Modular mobile heat generation unit for generation of geothermal power in organic Rankine cycle operations

ABSTRACT

Systems and methods for generating electrical power in an organic Rankine cycle (ORC) operation include one or more heat exchangers incorporated into mobile heat generation units, and which will receive a heated fluid flow from one or more heat sources, and transfer heat therefrom to a working fluid that is circulated through an ORC unit for generation of power. In embodiments, the mobile heat generation units comprise pre-packaged modules with one or more heat exchangers connected to a pump of a recirculation system, including an array of piping, such that each mobile heat generation unit can be transported to the site and installed as a substantially stand-alone module or heat generation assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/657,721, filed Apr. 1, 2022, titled “Modular Mobile HeatGeneration Unit for Generation of Geothermal Power in Organic RankineCycle Operations,” which claims priority to and the benefit of U.S.Provisional Application No. 63/269,862, filed Mar. 24, 2022, titled“Systems and Methods for Generation of Electrical Power at a DrillingRig,” and U.S. Provisional Application No. 63/269,572, filed Mar. 18,2022, titled “Systems and Methods for Generation of Electrical Power ata Drilling Rig,” U.S. Provisional Application No. 63/261,601, filed Sep.24, 2021, titled “Systems and Methods Utilizing Gas Temperature as aPower Source,” and U.S. Provisional Application No. 63/200,908, filedApr. 2, 2021, titled “Systems and Methods for Generating GeothermalPower During Hydrocarbon Production,” the disclosures of all of whichare incorporated herein by reference in their entireties. U.S.Non-Provisional application Ser. No. 17/657,721 is also acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/657,009, filed Mar. 29, 2022, titled “Systems and Methods forGeneration of Electrical Power at a Drilling Rig,” which claims priorityto and the benefit of U.S. Provisional Application No. 63/269,862, filedMar. 24, 2022, titled “Systems and Methods for Generation of ElectricalPower at a Drilling Rig,” and U.S. Provisional Application No.63/269,572, filed Mar. 18, 2022, titled “Systems and Methods forGeneration of Electrical Power at a Drilling Rig,” U.S. ProvisionalApplication No. 63/261,601, filed Sep. 24, 2021, titled “Systems andMethods Utilizing Gas Temperature as a Power Source,” and U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 is also a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/305,297, filed Jul. 2, 2021, titled “Systems forGenerating Geothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production Based on Working Fluid Temperature,” which claimspriority to and the benefit of U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009is a continuation-in-part of U.S. Non-Provisional application Ser. No.17/578,520, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” now U.S. Pat. No. 11,326,550, issuedMay 10, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/261,601, filed Sep. 24, 2021, titled“Systems and Methods Utilizing Gas Temperature as a Power Source,” andU.S. Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 also further is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/578,528, filed Jan. 19, 2022,titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” which claims priority to and the benefit of U.S. ProvisionalApplication No. 63/261,601, filed Sep. 24, 2021, titled “Systems andMethods Utilizing Gas Temperature as a Power Source,” and U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 still further is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/578,542, filed Jan. 19, 2022,titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” now U.S. Pat. No. 11,359,576, issued Jun. 14, 2022, whichclaims priority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009additionally is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,550, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009is also a continuation-in-part of U.S. Non-Provisional application Ser.No. 17/650,811, filed Feb. 11, 2022, titled “Systems for GeneratingGeothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production Based on Wellhead Fluid Temperature,” which is acontinuation of U.S. Non-Provisional application Ser. No. 17/305,298,filed Jul. 2, 2021, titled “Controller for Controlling Generation ofGeothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production,” now U.S. Pat. No. 11,280,322, issued Mar. 22,2022, which claims priority to and the benefit of U.S. ProvisionalApplication No. 63/200,908, filed Apr. 2, 2021, titled “Systems andMethods for Generating Geothermal Power During Hydrocarbon Production,”the disclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009further still is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/670,827, filed Feb. 14, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” now U.S. Pat. No. 11,421,663, issued Aug. 23, 2022,which is a continuation-in-part of U.S. Non-Provisional application Ser.No. 17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 yet further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/682,126, filed Feb. 28, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” now U.S. Pat. No. 11,359,612, issued Jun. 14, 2022,which is a continuation of U.S. Non-Provisional application Ser. No.17/494,936, filed Oct. 6, 2021, titled “Systems and Methods forGeneration of Electrical Power in an Organic Rankine Cycle Operation,”now U.S. Pat. No. 11,293,414, issued Apr. 5, 2022, which is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties.

FIELD OF DISCLOSURE

Embodiments of this disclosure relate to generating geothermal power,and more particularly, to a modular heat exchange assembly for use aspart of systems and methods for generating and controlling generation ofgeothermal power in an organic Rankine cycle (ORC) operation that can beoperated in the vicinity of a hydrocarbon production operation tothereby supply electrical power to one or more of in-field operationalequipment, a grid power structure, and an energy storage device.

BACKGROUND

Organic Rankine cycle (ORC) operations have been used for generation ofpower in applications such as for hydrocarbon production at pumpingstations and/or in the vicinity of wellhead operations. Typically, ORCgenerators utilize a working fluid loop that flows in a loop wherein theworking fluid is heated to cause the working fluid in the loop to changephases from a liquid to a vapor. The vaporous working fluid may thenflow to a gas expander, causing the gas expander to rotate. The rotationof the gas expander may cause a generator to generate electrical power.The vaporous working fluid may then flow to a condenser or heat sink.The condenser or heat sink may cool the working fluid, causing theworking fluid to change phase from the vapor to the liquid. The workingfluid may circulate through the loop in such a continuous manner, thusthe geothermal generator may generate electrical power.

Heat exchangers within geothermal generators often are not built towithstand high pressures, and/or substantial heat flows. In addition,construction of ORC power systems in the field can be difficultparticularly to provide and/or construction such power systems quicklyand with sufficient capacity for a desired level of power generation. Itfurther can be difficult to modify and/or change components in thefield, particularly at more remote sites.

Accordingly, Applicants have recognized a need for systems and methodsfor generation of power in an organic Rankine cycle (ORC) operation thatincludes components and/or systems to facilitate ease of constructionand/or customizable power generation systems for supplying electricalpower to one or more of in-field operational equipment, a grid powerstructure, and an energy storage device. The present disclosure isdirected to embodiments of such systems and methods.

SUMMARY

The present disclosure is generally directed to systems and methods forgenerating and controlling generation of electrical power in an organicRankine cycle (ORC) operation at a remote site, such as in the vicinityof a wellhead during hydrocarbon production to thereby supply electricalpower to one or more of in-field operational equipment, a grid powerstructure, and an energy storage device. In embodiments, the presentdisclosure provides a mobile heat generation unit that is constructedwith a series of components to provide a transportable module that canbe transported and located at a site, such as a site for hydrocarbonproduction.

By way of example and not limitation, in embodiments, the hydrocarbonproduction site can include a wellhead and/or pumping station thatproduces a heated wellhead fluid that, as it exits the wellhead, may beunder high-pressure and at a high temperature. Other heated liquid orheated gas flows also are produced by various in-field components orequipment, such as fracturing equipment, pumpjacks, compressors,drilling rigs, engines used to drive pumps, gas coolers, or compressors,etc. In an embodiment, such equipment can act as a heat source or supplyof a heated fluid, e.g. a high temperature or high pressure gas orliquid, and can be coupled or connected to the modular mobile heatgeneration unit that can be supplied to the site as a pre-configuredunit or module including at least one heat exchanger. The at least oneheat exchanger may be a high-pressure heat exchanger configured towithstand the high-pressure of the wellhead fluid from a wellhead andindirectly transfer heat from the flow of the wellhead fluid to the flowof a working fluid. Other types of heat exchangers configured totransfer heat from other heat sources, such as heated exhaust gases fromone or more engines at the site driving pumps or compressors, to aworking fluid.

In embodiments, the mobile heat generation unit can be formed with atleast two heat exchangers that can be selected based upon siterequirements and installed with a substantially standardized series ofcomponents for transport as a pre-packaged unit or module that is easilytransported to the site and installed or “plugged-in” as a component ofa geothermal power generation system. The mobile heat generation unitcan be transported to a site, such as a drilling, fracking or pumpingsite, as an effectively pre-packaged, standalone module or unit, and inembodiments, can be configured with a working footprint of approximatelythe size of a shipping container, e.g. being formed as a cube orsubstantially rectangular container.

At the site, the mobile heat generation unit will be connected to theone or more heat sources, such as by ducting or piping, to receive aheated fluid flow therefrom; and further will be connected to an ORCunit in a substantially closed loop. As heat is transferred from theincoming heated fluid flow, e.g. the wellhead fluid, exhaust gas, etc.,to the working fluid passing through the mobile heat generation unit,the at least one heat exchanger causes heat from the heated fluid flowto be transferred to the working fluid to cause it to be substantiallyheated from its liquid phase to or close to a vapor phase. The heatedworking fluid flows through the ORC unit to drive operation of agenerator to generate electrical power via rotation of a gas expander ofthe ORC unit. Such an operation may be defined as or may be an ORCoperation or process. The ORC unit further may be an off-the-shelf unit,connectable to the mobile heat generation unit as a stand-alonecomponent or device.

Accordingly, aspects of the present disclosure include a system forgenerating power in an organic Rankine cycle (ORC) operation,comprising: at least one ORC unit configured to generate electricalpower; and at least one mobile heat generation unit in fluidcommunication with at least one ORC unit and with one or more heatsources supplying a high pressure or high temperature fluid to the heatexchange unit; wherein the mobile heat generation unit is configured asa transportable module and comprises: a frame having an upper portion, alower portion and a plurality of sides defining a chamber; at least oneheat exchanger mounted within the chamber and connected to at least oneof the one or more heat sources; a fluid recirculation system at leastpartially located within the chamber and comprising: a fluid intakeconduit coupled to a return line in fluid communication with the atleast one ORC unit for receiving a working fluid at a first temperaturefrom the at least one ORC unit; a fluid outlet conduit coupled to aheated fluid supply line in fluid communication with the at least oneORC unit for supplying the working fluid thereto, wherein the workingfluid is output to the fluid supply line for supply to the ORC unit at asecond temperature that is higher than the first temperature; a pumpconnected to the fluid intake conduit and configured to pump the workingfluid received through the fluid intake conduit through the fluidrecirculation system; and a piping array, including a first section ofpiping extending between the pump and the at least one heat exchangerfor supplying the working fluid to the at least one heat exchanger, anda second section of piping extending between the at least one heatexchanger and the fluid outlet conduit; wherein as the working fluidpasses along the piping array and through the at least one heatexchanger, heat from the high pressure or high temperature fluidsupplied to the at least one heat exchanger from the one or more heatsources is transferred to the working fluid so as to heat the workingfluid to a second temperature that is greater than the firsttemperature; and a controller positioned within the frame, thecontroller having programming configured to monitor temperature,pressure, or a combination thereof of a working fluid passing along afluid recirculation loop defined between the mobile heat generation unitand at least one ORC unit, and for regulating flow of the working fluidthrough the at least one heat exchanger for transfer of heat from theflow of a heated fluid to the working fluid for supply to the at leastone ORC unit.

In embodiments, the controller can include programming configured tocommunicate with one or more sensors configured to monitor temperatureand pressure of the working fluid passing through the piping array, and,in response to readings from such sensors, control operation of the pumpfor regulating flow of the working fluid through the piping array and atleast one heat exchanger to substantially maximize the transfer of heatto the working fluid supplied to the at least one ORC unit withoutsubstantially vaporizing the working fluid.

In embodiments of the system, the at least one mobile heat generationunit includes at least two heat exchangers configured to extract heatfrom a compressed gas, a heated exhaust gas, a heated liquid, orcombination thereof. In some embodiments, the at least one heatexchanger is mounted within the chamber at an elevated position adjacentthe upper portion of the frame.

In some embodiments of the system, the at least one mobile heatgeneration unit further comprises an air separator along the secondsection of piping, the air separator configured to remove penetratesfrom the working fluid.

In embodiments of the system, the at least one mobile heat generationunit has a length of at least approximately fifteen feet. In otherembodiments, the at least one mobile heat generation unit has a lengthof between approximately fifteen feet and approximately forty feet. Insome embodiments, the at least one mobile heat generation unit comprisesa substantially square or a substantially rectangular shape.

In embodiments of the system, the at least one mobile heat generationunit further comprises a plurality of cover panels positioned along theupper and lower portions and the sides of the frame, so as tosubstantially enclose the chamber, wherein at least some of the coverpanels are configured to be removable from the frame to enable access tothe chamber. In some embodiments, one or more of the cover panels alongthe upper portion are removable to enable removal and replacement of theat least one heat exchanger.

In embodiments of the system, the at least one mobile heat generationunit further comprises an expansion tank located in fluid communicationwith the second section of piping, wherein the controller includesprogramming configured to regulate flow of the working fluid into theexpansion tank so as to reduce the pressure of the working fluid.

In embodiments of the system, the chamber of the frame comprises aplurality of quadrants including at least a first quadrant defining acontrol cabinet housing the controller, and a second quadrant defining aworking area in which the at least one heat exchanger and the fluidrecirculation system are located.

In embodiments, the system further comprises a power and data connectionextending between the at least one ORC unit and the at least one mobileheat generation unit; wherein the at least one ORC unit includes acontroller; and wherein the controller of the at least one mobile heatgeneration unit is couple to the controller of the at least one ORCunit.

In embodiments, the at least one mobile heat generation unit furthercomprises a backup power system configured to supply power to thecontroller and for operation of one or more dump valves for release ofthe working fluid from the fluid recirculation system upon loss of powerfrom a direct power supply.

In another aspect, a system for generating geothermal power in anorganic Rankin cycle (ORC) operation in the vicinity of a wellheadduring hydrocarbon production for supplying electrical power to in-fieldequipment, a grid power structure, energy storage devices, orcombinations thereof, is provided, the system comprising at least onemobile heat generation unit; one or more conduits configured to divert aflow of heated fluid from one or more heat sources to the at least onemobile heat generation unit; wherein the at least one mobile heatgeneration unit comprises at least one heat exchanger; a pump configuredto pump a flow of a working fluid through the at least one heatexchanger; and a first fluid path extending through the at least oneheat exchanger and along which the flow of heated fluid is received fromat least one of the one or more conduits and is directed through the atleast one heat exchanger, and a second fluid path extending through theat least one heat exchanger and along which the flow of a working fluiddirected through the at least one heat exchanger for indirectlytransferring heat from the flow of heated fluid passing through the atleast one heat exchanger along the first fluid path to the flow of theworking fluid passing through the at least one heat exchanger along thesecond fluid path to cause the working fluid be heated so as to changephases from a liquid substantially to a vapor; and an ORC unit includinga generator, a gas expander, pump, and a partial flow path for the flowof the working fluid through the gas expander, generator, and pump;wherein a substantially closed fluid recirculation loop for the workingfluid is defined between the at least one mobile heat generation unitand the ORC unit when connected to the second fluid path of the mobileheat generation unit; wherein the flow of the heated working fluid intothe ORC unit causes the generator thereof to generate electrical powervia rotation of the gas expander of the ORC operation, after which theworking fluid is cooled so as to cause the working fluid to changephases to the liquid phase, whereupon the liquid state working fluid isrecirculated back to the at least one mobile heat generation unit forreheating; and wherein the at least one heat mobile heat generation unitcomprises a transportable pre-packaged module.

In embodiments, the at least one mobile heat generation unit includes asubstantially rectangular frame defining a working footprint having alength of approximately fifteen feet to approximately twenty feet, and awidth of at least about eight feet.

In embodiments, the at least one mobile heat generation unit includes atleast two heat exchangers configured to extract heat from a compressedgas, a heated exhaust gas, a heated liquid, or combination thereof.

In another aspect of the present disclosure, a mobile heat generationunit is provided for use in generating heat for an organic Rankine cycle(ORC) power operation for generation of electrical power, and cancomprise a transportable package including a frame defining a footprint,the package further comprising at least one heat exchanger; a connectingpipe extending between the at least one heat exchanger and a heat sourceand configured to direct a flow of a high pressure or high temperaturefluid from the heat source to the at least one heat exchanger; acontroller having programming configured to monitor temperature,pressure, or a combination thereof of a working fluid passing along afluid recirculation loop defined between the mobile heat generation unitand at least one ORC unit, and for regulating flow of the working fluidthrough the at least one heat exchanger for transfer of heat from theflow of the high pressure or high temperature fluid to the workingfluid; and a fluid recirculation system comprising a fluid intakeconduit coupled in fluid communication with the at least one ORC unitfor receiving the working fluid at a first temperature from the at leastone ORC unit; a fluid outlet conduit in fluid communication with the atleast one ORC unit for supplying the working fluid thereto, wherein theworking fluid is supplied to the ORC unit at a second temperature thatis higher than the first temperature; a pump connected to the fluidintake conduit, the pump and configured to pump the working fluidreceived through the fluid intake conduit through the fluidrecirculation system; and a piping array, including a first section ofpiping extending between the pump and the at least one heat exchangerfor supplying the working fluid to the at least one heat exchanger, anda second section of piping extending between the at least one heatexchanger and the fluid outlet conduit; and wherein as the working fluidpasses along the piping array and through the at least one heatexchanger, heat from the high pressure or high temperature fluidsupplied to the at least one heat exchanger from the heat source istransferred to the working fluid so as to heat the working fluid to thesecond temperature for supply to the at least one ORC unit.

In embodiments of the mobile heat generation unit, the frame comprisesupper and lower portions and sides defining a chamber, and a pluralityof cover panels positioned along the upper and lower portions and thesides of the frame, so as to substantially enclose the chamber, whereinat least some of the cover panels are configured to be removable fromthe frame to enable access to the chamber. In some embodiments, the atleast one mobile heat generation unit includes a frame defining aworking foot print having a length of approximately 15 to approximately20 feet, and a width of at least about 8 feet.

In embodiments, the mobile heat generation unit further comprises apower and data connection extending between the at least one ORC unitand the at least one mobile heat generation unit for transmission ofpower and data between the at least one ORC unit and at least one mobileheat generation unit; wherein the at least one ORC unit includes acontroller; and wherein the controller of the at least one mobile heatgeneration unit is coupled to the controller of the at least one ORCunit.

In embodiments, the mobile heat generation unit further comprises abackup power system configured to supply power to the unit controller, aseries of sensors, including one or more sensors adopted to monitorambient environment weather condition of one or more drainage valves forrelease of the working fluid from the fluid recirculation system uponloss of power from a direct power supply.

According to another aspect, an embodiment of the disclosure is directedto a method for generating geothermal power in an organic Rankine cycle(ORC) operation in the vicinity of a wellhead during hydrocarbonproduction to thereby supply electrical power to one or more of in-fieldoperational equipment, a grid power structure, and an energy storagedevice. The method may include, prior to hydrocarbon production,opening, to at least a partially opened position, one or more heatexchanger valves positioned between one or more heat exchangers and awellhead fluid flow line. The method may include, during hydrocarbonproduction at a wellhead, determining, based on feedback from one ormore temperature sensors, a temperature of an organic working fluid in aworking fluid flow line, the temperature of the organic working fluidbased on heat transfer from a flow of wellhead fluid from the wellheadto the organic working fluid. The method may include, in response to adetermination that the temperature of the organic working fluid isgreater than or equal to a vaporous phase change threshold of an organicworking fluid, maintaining the at least partially open position of theone or more heat exchanger valves to allow continuous diversion of theflow of the wellhead fluid to one or more heat exchangers to facilitatetransfer of heat from the flow of the wellhead fluid to the organicworking fluid through the one or more heat exchangers, thereby to changephases of the organic working fluid from a liquid to a vapor within theone or more heat exchangers so as to cause a gas expander, in fluidcommunication with the one or more heat exchangers, to rotate agenerator to generate electrical power from the ORC operation.

In embodiments, the temperature of the organic working fluid may bedetermined continuously or at one or more time intervals. The timeintervals may be one or more of 1 minute, 5 minutes, 10 minutes, 20minutes, 30 minutes, or 1 hour. The method may include, in response to adetermination that the temperature of the organic working fluid at eachof a specified number of the one or more time intervals is less than thevaporous phase change threshold, opening a wellhead fluid valve andclosing the one or more heat exchanger valves. The specified number ofthe one or more time intervals may be equivalent to at least 6determinations of the temperature of the organic working fluid over 1hour, at least 6 determinations of the temperature of the organicworking fluid over 2 hours, or at least 12 determinations of thetemperature of the organic working fluid over 3 hours.

In another embodiment, the method may include, in response to theopening of the wellhead fluid valve and closing of the one or more heatexchanger valves, determining a temperature of the flow of the wellheadfluid. The method may further include, in response to a determinationthat the temperature of the flow of the wellhead fluid is greater thanor equal to the vaporous phase change temperature, opening the one ormore heat exchanger valves and closing the wellhead fluid valve.

In another embodiment, the method may include determining a flow rateand a pressure of the flow of the wellhead fluid from the wellhead. Themethod may include determining a flow rate and a pressure of the flow ofthe wellhead fluid from the one or more heat exchangers. The method mayfurther include adjusting the one or more heat exchanger valves andwellhead fluid valve to meet a production threshold, based on flow rateand pressure of the flow of the wellhead fluid from the wellhead andfrom the one or more heat exchangers.

In another embodiment, the one or more heat exchangers and the generatorin combination may be included in and collectively defined as an ORCunit and wherein the ORC unit comprises a modular single-pass ORC unit.The ORC unit may be configured to connect to and interface with one ormore other ORC units based on one or more of power demands and the flowof the wellhead fluid from the wellhead. The one or more of the one ormore heat exchangers may be stand-alone units and the generator may beincluded in and defines an ORC unit.

In an embodiment, the amount of the flow of wellhead fluid diverted maycomprise substantially an entire flow of wellhead fluid. The amount ofthe flow of wellhead fluid diverted may be based on one or more of thetemperature, flow rate, or pressure of the flow of wellhead fluid.

In an embodiment, the vaporous phase change threshold may be about 50degrees Celsius or higher. The one or more of the one or more heatexchangers may include (a) a high-pressure rated shell heat exchanger or(b) a high pressure rated tube heat exchanger.

In another embodiment, the method may include, in response to adetermination that the wellhead is producing wellhead fluid, determiningwhether the one or more heat exchanger valves are open. The method mayfurther include, in response to a determination that the one or moreheat exchanger valves are closed, adjustingly opening one or more heatexchanger valves and adjustingly closing the wellhead fluid valve to aselected, at least partially closed position to allow sufficient flow toprevent hydrocarbon production impact.

Another embodiment of the disclosure is directed to a method forgenerating geothermal power in an organic Rankin cycle operation in thevicinity of a wellhead during hydrocarbon production to thereby supplyelectrical power to one or more of in-field operational equipment, agrid power structure, and an energy storage device. The method mayinclude connecting one or more high-pressure heat exchangers to awellhead fluid flow line of one or more wellheads at a well therebydefining a fluid path from the wellhead fluid flow line of one or morewellheads through the one or more high pressure heat exchangers. Themethod may include connecting one or more ORC units to the one or morehigh-pressure heat exchangers. In embodiments, the ORC unit may be anoff-the-shelf unit, connectable to one or more heat exchangers, while inother embodiments, the ORC unit may be a high-pressure ORC unit and mayinclude the high-pressure heat exchanger apparatus.

The method may include opening one or more heat exchanger valvespositioned between the one or more heat exchangers and wellhead fluidflow line of one or more wellheads, to allow continuous diversion of theflow of the one or more wellhead fluids during hydrocarbon production tothe one or more high-pressure heat exchangers to facilitate transfer ofheat from a flow of the one or more wellheads fluid from the one or morewellheads to a flow of working fluid through the one or morehigh-pressure heat exchangers, thereby to change phases of the organicworking fluid from a liquid to a vapor within the one or more heatexchangers so as to cause a gas expander, in fluid communication withthe one or more heat exchangers, to rotate a generator to generateelectrical power from the ORC operation. The method may include duringhydrocarbon production at one or more of the one or more wellheads,determining, based on feedback from one or more temperature sensorscorresponding to the flow of working fluid exiting the one or morehigh-pressure heat exchangers to a corresponding ORC unit, a temperatureof the flow of the working fluid. The method may include, in response toa determination that the temperature is above a vaporous phase changethreshold of the working fluid, maintaining at least a partially openedposition of the one or more heat exchanger valves.

In another embodiment, an intermediary heat exchanger connects one ormore of the high-pressure heat exchangers to the one or more ORC units,the intermediary heat exchanger including an intermediary working fluidincluding a vaporous phase change threshold greater than that of thevaporous phase change threshold of the working fluid. The one or morehigh-pressure heat exchangers facilitate transfer of heat from the flowof the one or more wellhead fluids to the intermediary working fluid,and wherein the intermediary heat exchanger facilitates transfer of heatfrom the intermediate working fluid to the working fluid.

In another embodiment, the one or more ORC units are modular and mobileand the one or more high-pressure heat exchangers are modular andmobile.

In another embodiment, the method of may include, in response to adetermination that the temperature is below a vaporous phase changethreshold of the working fluid, adjustingly increasing an open positionof the one or more heat exchanger valves. The method may furtherinclude, in response to an increased open position of the one or moreheat exchanger valves and a determination that the temperature is belowthe vaporous phase change threshold of the working fluid, opening one ormore wellhead fluid valves and closing the one or more heat exchangervalves.

In other aspects, a method for generating geothermal power in an organicRankin cycle operation during hydrocarbon production to supplyelectrical power to one or more of in-field operational equipment, agrid power structure, and an energy storage device comprises locatingone or more mobile heat generation units at a hydrocarbon productionsite; wherein the one or more mobile heat generation units each comprisea package having at least one heat exchanger, a controller, and a fluidrecirculation system including a pump, a fluid inlet conduit throughwhich a flow of a working fluid is received in a substantially liquidphase, a fluid outlet conduit through which the working fluid issupplied in a substantially vapor phase, and an array of piping defininga fluid path extending from the pump through the at least one heatexchanger and to the fluid outlet conduit; connecting the at least oneheat exchanger of the one or more mobile heat generation units to a heatsource thereby defining a fluid path extending from the heat sourcethrough the at least one heat exchanger; connecting one or more ORCunits to the at least one heat exchanger; opening one or more valvespositioned between the at least one heat exchanger and the heat sourceconnected thereto to enable a flow of heated fluid along the fluid pathextending from the heat source through the at least one heat exchanger,and pumping the working fluid along the fluid path extending from thepump through the at least one heat exchanger and to the fluid outletconduit; wherein the at least one heat exchanger transfers heat from theflow of heated fluid to the working fluid pumped through the at leastone heat exchanger, to cause a change in phase of the working fluid froma liquid to a vapor, which is thereafter supplied to the one or more ORCunits to drive a generator for generation of electrical power from theORC operation.

In embodiments, the method may include connecting one or more ORC unitsto the one or more high-pressure heat exchangers of one or more mobileheat generation units. The method may include opening one or more heatexchanger valves positioned between the one or more heat exchangers anda wellhead fluid flow line of one or more wellheads, to allow continuousdiversion of the flow of the one or more wellhead fluids duringhydrocarbon production to the one or more high-pressure heat exchangersto facilitate transfer of heat from a flow of the one or more wellheadsfluid from the one or more wellheads to a flow of working fluid throughthe one or more high-pressure heat exchangers, thereby to change phasesof the organic working fluid from a liquid to a vapor within the one ormore heat exchangers so as to cause a gas expander, in fluidcommunication with the one or more heat exchangers, to rotate agenerator to generate electrical power from the ORC operation.

In embodiments, the method also may include, during hydrocarbonproduction at one or more of the one or more wellheads, intermittentlydetermining, based on feedback from one or more temperature sensorscorresponding to the flow of working fluid exiting the one or morehigh-pressure heat exchangers to a corresponding ORC unit, a temperatureof the flow of the working fluid. The method may include, in response toa determination that the temperature is above a vaporous phase changethreshold of the working fluid, maintaining at least a partially openedposition of the one or more heat exchanger valves. In some embodiments,the method may further include, in response to a determination that aseries of the intermittently determined temperatures of the flow ofworking fluid each is below a vaporous phase change threshold, opening awellhead fluid valve positioned at a point on the wellhead fluid flowline to allow wellhead fluid to flow therethrough and closing the one ormore heat exchanger valves.

In other embodiments, the method may include, in response to the closingof the one or more heat exchanger valves, determining, based on feedbackfrom one or more temperature sensors corresponding to the flow ofwellhead fluid flowing through the wellhead fluid line, a temperature ofthe flow of the wellhead fluid flow, and, in response to a determinationthat the temperature is above a vaporous phase change threshold, openingthe one or more heat exchanger valves and closing the wellhead fluidvalve to an at least partially closed position during hydrocarbonproduction at one or more of the one or more wellheads

In another embodiment, one or more pressure transducers are positionedalong the wellhead fluid line in proximity to each of the one or morewellheads and wherein a flow meter is positioned along the wellheadfluid line at a point downstream corresponding to the flow of wellheadfluid exiting the one or more high-pressure heat exchangers to thewellhead fluid line. The at least partially closed position of thewellhead fluid valve may be determined based on a production thresholdand a flow rate based on feedback from the flow meter to therebymaintain the flow of wellhead fluid above or at the productionthreshold.

In another embodiment, the method may include determining, based onfeedback from the one or more pressure transducers, a pressure at eachof the one or more heat exchangers; and, in response to the pressure atany of the one or more heat exchangers exceeding a pressure threshold ofthe corresponding one or more heat exchanger, if the wellhead fluidvalve is completely closed, opening the wellhead fluid valve to at leasta partially open position and closing the one or more heat exchangervalves.

In another embodiment, the method may include in further response to thepressure at any of the one or more heat exchangers exceeding a pressurethreshold of the corresponding one or more heat exchanger, opening acorresponding pressure relief valve positioned on each of the one ormore heat exchangers to thereby prevent damage to the corresponding oneor more heat exchanger.

In an embodiment, the pressure threshold may be up to about 15,000pounds per square inch (PSI). The working fluid may include one or moreof pentafluoropropane, carbon dioxide, ammonia and water mixtures,tetrafluoroethane, isobutene, propane, pentane, perfluorocarbons, andother hydrocarbons. The wellhead fluid may include hydrocarbons. Thewellhead fluid may further include a mixture of the hydrocarbons and oneor more of water and other chemical residuals.

Yet another aspect of the disclosure is directed to a method forgenerating geothermal power in an organic Rankin cycle operation in thevicinity of a wellhead during hydrocarbon production to thereby supplyelectrical power to one or more of in-field operational equipment, agrid power structure, and an energy storage device. The method mayinclude connecting one or more high-pressure heat exchangers to a heatsource. In embodiments, the heat source can include a wellhead fluidflow supply line that provides a flow of wellhead fluid from one or morewellheads at a well, defining a fluid path from the wellhead fluid flowline of one or more wellheads through the one or more high pressure heatexchangers. In other embodiments, the heat source can include highpressure or high temperature liquid or gas flows, such as, for example,exhaust gases from natural gas or other fuel driven engines. Inaddition, in embodiments, the heat exchangers can be provided as part ofa mobile heat generation unit that can comprise a pre-packaged modulewith one or more heat exchangers connected to a pump of a fluidrecirculation system, including an array of piping, which mobile heatgeneration unit can be transported to the site and installed as asubstantially stand-alone module or heat generation assembly. In otherembodiments, the heat exchangers can be provided separately.

The method may include connecting an ORC unit to the one or morehigh-pressure heat exchangers, e.g. the heat exchangers of one or moremobile heat generation units. The method may include opening one or moreheat exchanger valves positioned between the one or more heat exchangersand wellhead fluid flow line of one or more wellheads, to allowcontinuous diversion of the flow of the one or more wellhead fluidsduring hydrocarbon production to the one or more high-pressure heatexchangers to facilitate transfer of heat from a flow of the one or morewellheads fluid from the one or more wellheads to a flow of workingfluid through the one or more high-pressure heat exchangers. The methodmay include opening, to an at least partially open position, one or moreORC unit valves to allow the flow of working fluid to flow into the ORCunit to thereby generate electrical power from the ORC operation of theORC unit. The method may include, during hydrocarbon production at oneor more of the one or more wellheads, intermittently determining, basedon feedback from one or more temperature sensors corresponding to theflow of working fluid exiting the one or more high-pressure heatexchangers to the ORC unit, a temperature of the flow of the workingfluid. The method may include determining an efficient working fluidflow for each of the one or more high-pressure heat exchangers based onthe temperature of the flow of the working fluid from each of the one ormore high-pressure heat exchangers and the open position of each of theone or more ORC unit valves. The method may include adjusting the atleast partially open position of the one or more ORC unit valves basedon the efficient working fluid flow for each of the one or morehigh-pressure heat exchangers. In another embodiment, the efficientworking fluid flow for each of the one or more high-pressure heatexchangers may be based on electrical power output of the ORC unit.

According to other aspects of the present disclosure, a system forgenerating geothermal power in the vicinity of a wellhead duringhydrocarbon production to thereby supply electrical power to one or moreof in-field equipment, a grid power structure, and energy storagedevices is provided. In embodiments, the system can comprise a firstpipe connected to and in fluid communication with a heat source, such asbeing coupled to the wellhead that can supply high-pressure wellheadfluid to the system for providing heat to generate power; wherein thefirst pipe is configured to transport wellhead fluid underhigh-pressure; a first wellhead fluid valve having a first end andsecond end, the first end of the first wellhead fluid valve connected toand in fluid communication with the first pipe, the first wellhead fluidvalve to control flow of wellhead fluid based on an organic workingfluid temperature; a heat exchanger valve connected to and in fluidcommunication with the first pipe, the heat exchanger valve to controlflow of wellhead fluid on an organic working fluid temperature; ahigh-pressure heat exchanger to accept the flow of wellhead fluid whenthe heat exchanger valve is open, the high-pressure heat exchangerincluding a first opening and a second opening connected via a firstfluidic path and a third opening and a fourth opening connected via asecond fluidic path, the first fluidic path and the second fluidic pathto facilitate heat transfer from the flow of wellhead fluid to anorganic working fluid, the transfer of heat from the wellhead fluid tothe organic working fluid to cause the organic working fluid to changephases from a liquid to a vapor, the flow of wellhead fluid flowing intothe first opening of the high-pressure heat exchanger from the heatexchanger valve through the first fluidic path and to the second openingof the high-pressure heat exchanger, and a flow of the organic workingfluid flowing into the third opening through the second fluidic path andout of the fourth opening; a first temperature sensor connected to thefourth opening, the first temperature sensor to provide the organicworking fluid temperature, the organic working fluid temperature definedby a temperature of organic working fluid flowing through the secondfluidic path; a second pipe connected to and in fluid communication withthe second end of the first wellhead fluid valve and connected to and influid communication with the second opening of the high-pressure heatexchanger; a generator connected to and in fluid communication with thefourth opening of the high-pressure heat exchanger, the organic workingfluid flowing from the fourth opening to the generator and causing thegenerator to generate electrical power via rotation of a vapor expanderas defined by an ORC operation; a condenser to facilitate heat transferfrom the organic working fluid to a coolant; and a pump connected to thecondenser to pump the organic working fluid from the condenser to thethird opening of the high-pressure heat exchanger.

In embodiments, the heat source can include the flow of wellhead fluidfrom one or more wellheads at a well, being directed along a fluid pathfrom the wellhead fluid flow line of one or more wellheads through thefirst pipe one or more high pressure heat exchangers. In otherembodiments, the heat source can include high pressure or hightemperature liquid or gas flows, such as, for example, exhaust gasesfrom natural gas or other fuel driven engines. In addition, inembodiments, the heat exchangers can be incorporated into mobile heatgeneration units, which further can include multiple high pressure heatexchangers. In embodiments, the mobile heat generation units comprise apre-packaged module with one or more heat exchangers connected to a pumpof a fluid recirculation system, including an array of piping, whichmobile heat generation unit can be transported to the site and installedas a substantially stand-alone module or heat generation assembly. Inother embodiments, the heat exchangers can be provided separately.

Each mobile heat generation unit comprises a substantiallypre-constructed or pre-packaged module or unit having a frame defining achamber in which a series of generally common components can bearranged, and can include one or more high pressure heat exchangers of aselected type and/or capacity, a first fluid path extending in a loopfrom the heat exchanger valve to the one or more heat exchangers forsupplying the heated wellhead fluid, and a second fluid path defined bya fluid recirculation system including a pump, a piping array, and fluidinlet and outlet conduits forming a circulation loop with an ORC unit,and though which a working fluid passes and is heated by transfer ofheat from the wellhead fluid in the one or more heat exchangers, and isdirected through the ORC unit for generation of power thereby, afterwhich the cooled working fluid is directed back into the at least onemobile heat generation unit.

Still other aspects and advantages of these embodiments and otherembodiments, are discussed in detail herein. Moreover, it is to beunderstood that both the foregoing information and the followingdetailed description provide merely illustrative examples of variousaspects and embodiments, and are intended to provide an overview orframework for understanding the nature and character of the claimedaspects and embodiments. Accordingly, these and other objects, alongwith advantages and features of the present invention herein disclosed,will become apparent through reference to the following description andthe accompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF DRAWINGS

These and other features, aspects, and advantages of the disclosure willbecome better understood with regard to the following descriptions,claims, and accompanying drawings. It is to be noted, however, that thedrawings illustrate only several embodiments of the disclosure and,therefore, are not to be considered limiting of the scope of thedisclosure.

FIG. 1A and FIG. 1B are schematic top-down perspectives of novelimplementations of a geothermal power generation enabled well, accordingto one or more embodiment of the disclosure.

FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D, FIG. 2E, FIG. 2F, FIG. 2G, and FIG.2H are block diagrams illustrating novel implementations of a geothermalpower generation enabled well to provide electrical power to one or moreof in-field equipment, equipment at other wells, energy storage devices,and the grid power structure, according to one or more embodiment of thedisclosure.

FIG. 3A and FIG. 3B are block diagrams illustrating other novelimplementations of a geothermal power generation enabled well to provideelectrical power to one or more of in-field equipment, equipment atother wells, energy storage devices, and the grid power structure,according to one or more embodiment of the disclosure.

FIG. 4A and FIG. 4B are simplified diagrams illustrating a controlsystem for managing geothermal power production at a well, according toone or more embodiment of the disclosure.

FIG. 5 is a flow diagram of geothermal power generation in which, when awellhead fluid is at or above a vaporous phase change temperature, heatexchanger valves may be opened to allow wellhead fluid to flowtherethrough, thereby facilitating heating of a working fluid for use inan organic Rankine cycle (ORC) unit, according to one or more embodimentof the disclosure.

FIG. 6 is another flow diagram of geothermal power generation in which,when a wellhead fluid is at or above a vaporous phase changetemperature, heat exchanger valves may be opened to allow wellhead fluidto flow therethrough, thereby facilitating heating of a working fluidfor use in a ORC unit, according to one or more embodiment of thedisclosure.

FIG. 7A is a flow diagram of geothermal power generation in which, whenan ORC fluid is at or above a vaporous phase change temperature, heatexchanger valves may remain open to allow wellhead fluid to flowtherethrough, thereby facilitating heating of a working fluid for use inan ORC unit, according to one or more embodiment of the disclosure.

FIG. 7B is another flow diagram of geothermal power generation in which,when an ORC fluid is at or above a vaporous phase change temperature,heat exchanger valves may remain open to allow wellhead fluid to flowtherethrough, thereby facilitating heating of a working fluid for use inan ORC unit, according to one or more embodiment of the disclosure.

FIG. 8 is a flow diagram of geothermal power generation in which aworking fluid flow is determined based on a preselected electrical poweroutput threshold, according to one or more embodiment of the disclosure.

FIG. 9A, FIG. 9B, FIG. 9C, FIG. 9D, FIG. 9E, FIG. 9F, and FIG. 9G areblock diagrams illustrating novel implementations of one or moregeothermal power generation enabled wells to provide electrical power toone or more of in-field equipment, equipment at one of the other wells,energy storage devices, and the grid power structure, according to oneor more embodiment of the disclosure.

FIGS. 10A-10D are perspective views of a mobile heat generation unit forheating of a working fluid for use in an organic Rankine cycle (ORC)unit for generation of power, according to one or more embodiments ofthe present disclosure.

FIG. 10E is a top plan view of the mobile heat generation unit of FIGS.10A-10D.

FIGS. 10F-10G are elevational views of the mobile heat generation unitof FIGS. 10A-10E.

FIG. 10H is a perspective view showing the application of cover panelsto the frame of the mobile heat generation unit.

FIG. 11 is a block diagram illustrating an example embodiment of theflow of a working fluid through an organic Rankine cycle (ORC) unit anda mobile heat generation unit such as illustrated in FIGS. 10A-10H forgeneration of power, according to one or more embodiments of the presentdisclosure.

FIGS. 12A-12G are additional views of embodiments of the mobile heatgeneration unit of FIGS. 10A-10G.

DETAILED DESCRIPTION

So that the manner in which the features and advantages of theembodiments of the systems and methods disclosed herein, as well asothers that will become apparent, may be understood in more detail, amore particular description of embodiments of systems and methodsbriefly summarized above may be had by reference to the followingdetailed description of embodiments thereof, in which one or more arefurther illustrated in the appended drawings, which form a part of thisspecification. It is to be noted, however, that the drawings illustrateonly various embodiments of the systems and methods disclosed herein andare therefore not to be considered limiting of the scope of the systemsand methods disclosed herein as it may include other effectiveembodiments as well.

The present disclosure is directed to systems and methods for generatinggeothermal power in an organic Rankine cycle (ORC) operation in thevicinity of a wellhead during hydrocarbon production to thereby supplyelectrical power to one or more of in-field equipment or operationalequipment, a grid power structure, other equipment, and an energystorage device. Wellhead fluids flowing from a wellhead at a well aretypically under high-pressure. In-field equipment at the well is notrated for such high pressures. Prior to further processing or transport,the pressure of the flow of the wellhead fluid may be reduced, e.g.,from 15,000 PSI to 200 PSI, from 10,000 PSI to 200 PSI, from 2,000 PSIto 200 PSI, or any other range from 20,000 PSI to 100 PSI, based on thepressure rating of the in-field equipment at the well. As the wellheadfluid flows from the wellhead, the temperature of the flow of thewellhead fluid may be at a high temperature, at least partially due tothe high pressure of the flow of the wellhead fluid. As the pressure isreduced, the wellhead fluid temperature may also be reduced, as resultof the pressure drop. Typically, the heat of the flow of wellhead fluidfrom the wellhead is not utilized and may be considered heat waste.

Geothermal power generators typically use a looping pipe or pipelineburied at depths with sufficient temperature to allow a working fluid tochange phase from liquid to vapor. As the working fluid changes phasefrom a liquid to a vaporous state, the vaporous state working fluid mayflow up the pipe or pipeline to a gas expander. The vaporous stateworking fluid may flow through and cause the gas expander to rotate. Therotation of the gas expander may cause a generator to generateelectrical power, as will be described below. The vaporous state workingfluid may flow through the gas expander to a heat sink, condenser, orother cooling apparatus. The heat sink, condenser, or other coolingapparatus may cool the working fluid thereby causing the working fluidto change phases from a vapor to a liquid. Heat exchangers of typicalgeothermal generators are not rated for high-pressure operations andusually geothermal generators obtain heat from varying undergrounddepths.

In the present disclosure, a high-pressure heat exchanger may be placedor disposed at the well and/or in the vicinity of one or more wellheads.The high-pressure heat exchanger may be connected to the wellhead andmay accept a high temperature or heated flow of wellhead fluid. Aworking fluid may flow through the heat exchanger. As the wellhead fluidand working fluid flows through the high-pressure heat exchanger, thehigh-pressure heat exchanger may facilitate transfer of heat from thewellhead fluid to the working fluid. A heat exchanger may include twofluidic paths, one for a heated fluid and another for a cool fluid. Thefluidic paths may be in close proximity, allowing heat to transfer fromthe heated fluid to the cool fluid. The fluidic paths may be loops,coils, densely packed piping, tubes, chambers, some other type of pathto allow for fluid to flow therethrough, and/or a combination thereof,as will be understood by those skilled in the art. As fluids flowthrough the heat exchanger, the cool liquid's temperature may increase,while the heated liquid's temperature may decrease.

Additionally, a geothermal generator unit or ORC unit may be disposed,positioned, or placed at the wellhead. The geothermal generator unit orORC unit may directly connect to the high-pressure heat exchanger,include the high-pressure heat exchanger, or may connect to thehigh-pressure heat exchanger via an intermediary heat exchanger. As thehot wellhead fluid heats the working fluid, either via direct connectionor through an intermediary heat exchanger, the working fluid may changephases from a liquid to a vapor. In such examples, the working fluidutilized may be chosen based on a low boiling point and/or highcondensing point. The vaporous state working fluid may flow through thegeothermal generator unit or ORC unit to a generator, e.g., a gasexpander and generator. The vaporous state working fluid may then flowto a condenser or heat sink, thereby changing state from the vapor tothe liquid. Finally, the liquid may be pumped back to the high-pressureheat exchanger. Such a cycle, process, or operation may be considered aRankine cycle or ORC.

Such systems may include various components, devices, or apparatuses,such as temperature sensors, pressure sensors or transducers, flowmeters, control valves, smart valves, valves actuated via controlsignal, controllers, a master or supervisory controller, other computingdevices, computing systems, user interfaces, in-field equipment, and/orother equipment. The controller may monitor and adjust various aspectsof the system to ensure that hydrocarbon production continues at aspecified rate, that downtime is limited or negligible, and thatelectrical power is generated efficiently, optimally, economically,and/or to meet or exceed a preselected electrical power outputthreshold.

FIGS. 1A and 1B are schematic top-down perspectives of novelimplementations of a geothermal power generation enabled well, accordingto one or more embodiment of the disclosure. As illustrated in FIG. 1A,a well 100 may include various components or equipment, also referred toas in-field equipment. Such in-field equipment may include fracturingequipment, field compressors, pump stations, artificial lift equipment,drilling rigs, data vans, and/or any other equipment utilized or used ata well 100. For example, the well 100 may include one or more pumpjacks108, one or more wellhead compressors 110, various other pumps, variousvalves, and/or other equipment that may use electrical power or othertype of power to operate. To generate power from otherwise wasted heat,the well 100 may additionally include a high-pressure heat exchanger104, one or more geothermal generators, one or more ORC units 106, ahigh-pressure geothermal generator, a high-pressure ORC unit, and/orsome combination thereof. As wellhead fluid flows from one of the one ormore wellheads 102, a portion of the flow of wellhead fluid or all ofthe flow of wellhead fluid may flow through the high-pressure heatexchanger 104, high-pressure geothermal generator, a high-pressure ORCunit, or some combination thereof. As the hot and high-pressure wellheadfluid flows through, for example, the high-pressure heat exchanger 104,the high-pressure heat exchanger 104 may facilitate a transfer of heatfrom the wellhead fluid to a working fluid flowing through thehigh-pressure heat exchanger 104. In other words, the wellhead fluid mayheat the working fluid. Such a heat transfer may cause the working fluidto change phases from a liquid to a vapor. The vaporous state workingfluid may flow from the high-pressure heat exchanger to the one or moreORC units 106. The one or more ORC units 106 may then generate powerusing the vaporous state working fluid. The electrical power may betransferred to the in-field equipment at the well 100, to an energystorage device (e.g., if excess power is available), to equipment atother wells, to the grid or grid power structure (e.g., via atransformer 116 through power lines 118), or some combination thereof.

As illustrated in FIG. 1B, one or more wells 100A, 100B, 100C may benearby or in close proximity to each of the other one or more wells100A, 100B, 100C. Further, each of the one or more wells 100A, 100B,100C may utilize different amounts of electrical power, in addition togenerating different amounts of electrical power. As such, one well(e.g., well 100A, well 100B, and/or well 100C) of the one or more wells100A, 100B, 100C may generate a surplus of electrical power or utilizeelectrical power from other sources. In an example, a controller maydetermine if a well (e.g., well 100A, well 100B, and/or well 100C) ofthe one or more wells 100A, 100B, 100C generates a surplus. If a surplusis generated, the controller may determine which, if any, of the otherone or more wells 100A, 100B, 100C may have a deficit of electricalpower. The controller may then transmit signals to equipment at the oneor more wells 100A, 100B, 100C to enable electrical power transferbetween the one or more wells 100A, 100B, 100C with excess and deficits,e.g., a well with a deficit may receive electrical power from a wellwith a surplus (see 120). In another example, the one or more wells100A, 100B, 100C may include energy storage devices e.g., batteries,battery banks, or other solutions to store energy for short or long termtime periods. The energy storage devices may be placed, disposed, orinstalled at one or more of the one or more wells 100A, 100B, 100C or atpoints in between the one or more wells 100A, 100B, 100C. As surpluselectrical power is generated, that surplus electrical power may betransmitted and stored in the energy storage devices. The energy storagedevices may be accessible by the in-field equipment of each of the oneor more wells 100.

As illustrated in FIGS. 1A and 1B, the one or more wells 100A, 100B,100C may include a high-pressure heat exchanger 104 and ORC units 106.In an example, the ORC units 106 may be modular and/or mobile. The ORCunits 106 may be mounted to a vehicle, such as a truck or other vehicletype, or skid and transported to the well 100. Further, thehigh-pressure heat exchanger 104 may be modular and/or mobile. Thehigh-pressure heat exchanger 104 may be mounted to a vehicle and/orskid. Upon arrival at one of the one or more wells 100A, 100B, 100C, thehigh-pressure heat exchanger 104 may be removed from the vehicle or thevehicle may be left on-site or at least while the one or more wells100A, 100B, 100C are producing hydrocarbons. In an example, duringhydrocarbon production, operation of the high-pressure heat exchanger104 and ORC unit 106 may occur. After hydrocarbon production has ceased,none, some, or all of the equipment may be removed from the well 100.For example, the well 100 may be re-used for generating geothermalenergy via a different method. In such examples the ORC units 106 andhigh-pressure heat exchanger 104 may remain on-site.

FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D, FIG. 2E, FIG. 2F, FIG. 2G, and FIG.2H are block diagrams illustrating novel implementations of a geothermalpower generation enabled well to provide electrical power to one or moreof in-field equipment, equipment at other wells, energy storage devices,and the grid power structure, according to one or more embodiment of thedisclosure. As illustrated in the FIGS. 2A through 2H, differentembodiments may be utilized for geothermal power generation at thesurface of a well during hydrocarbon production. As illustrated in FIG.2A, a well 200 may include a wellhead 202. The wellhead 202 may producea stream or flow of wellhead fluid. The wellhead fluid may flow from afirst pipe 215. The first pipe 215 may include, at various positionsalong the length of the pipe 215, sensors, meters, transducers, and/orother devices to determine the characteristics of the wellhead fluidflowing through pipe 215. Further, sensors, meters, transducers and/orother devices may be included at various positions within thehigh-pressure heat exchanger 250 and/or ORC unit 203 to determine thecharacteristics of the working fluid or ORC fluid flowing through thehigh-pressure heat exchanger 250 and/or ORC unit 203. Based on thedetermined characteristics of the wellhead fluid, working fluid, and/orORC fluid and/or characteristics of other aspects of the well 200, e.g.,temperature, pressure, flow, power demand and/or power storage ortransmission options and/or other factors, a first heat exchanger valve208 connected to the first pipe 215 may be opened, e.g., partiallyopened or fully opened.

Further, when the first heat exchanger valve 208 is opened, a secondheat exchanger valve 222 connected to a second pipe 217 may be opened,e.g., partially opened or fully opened. The second heat exchanger valve222 may allow the flow of wellhead fluid to exit the high-pressure heatexchanger 250. Based on the opening of the first heat exchanger valve208 and second heat exchanger valve 222, a first wellhead fluid valve210 may be adjusted. Such adjustment may occur to ensure that theproduction of the wellhead 202 or the production of wellhead fluid fromthe wellhead 202 may not be impeded or slowed based on a diversion ofthe flow of the wellhead fluid to the high-pressure heat exchanger 250.Downstream of the first wellhead fluid valve 210, but prior to where thediverted portion of the flow of wellhead fluid is reintroduced to theprimary or bypass wellhead fluid flow, a pressure sensor 212 may bedisposed, e.g., the pressure sensor 212 may be disposed along pipe 217.In another example, rather than a pressure sensor 212, a flow meter maybe disposed along pipe 217, e.g., a wellhead fluid flow meter and/or adownstream flow meter. The wellhead fluid flow meter may measure theflow rate of a fluid exiting the wellhead 202. A downstream flow metermay measure the flow rate of the wellhead fluid at a point downstream ofthe first wellhead fluid valve 210. Such a pressure sensor 212 or flowmeter may be utilized to determine whether the flow of wellhead fluid isat a pressure or flow that does not impede hydrocarbon production. In anexample, where the flow is impeded to a degree that the production ofhydrocarbons may be inhibited, the first wellhead fluid valve 210 may beopened further, if the first wellhead fluid valve 210 is not alreadyfully opened. If the first wellhead fluid valve 210 is fully opened, thefirst heat exchanger valve's 208 and second heat exchanger valve's 222percent open may be adjusted. Other factors may be taken into accountfor such determinations, such as the pressure or flow from thehigh-pressure heat exchanger 250, the pressure or flow at the point of achoke valve located further downstream along the second pipe 217, apressure rating for downstream equipment, and/or the temperature of thewellhead fluid within the high-pressure heat exchanger 250. Once theflow of wellhead fluid passes through the first wellhead fluid valve 210and/or the second heat exchanger valve 222, the wellhead fluid may flowto in-field equipment 270 for further processing or transport.

Each of the valves described herein, e.g., first heat exchanger valve208, second heat exchanger valve 222, first wellhead fluid valve 210,and other valves illustrated in the FIG. 2B through FIGS. 9G, may becontrol valves, electrically actuated valves, pneumatic valves, or othervalves suitable to receive signals and open and close under,potentially, high pressure. The valves may receive signals from acontroller or other source and the signals may cause the valves to moveto a partially or fully opened or closed position. The signal mayindicate the position that the valve may be adjusted to, e.g., aposition halfway open, a position a third of the way open, a position aparticular degree open, or completely open, such positions to beunderstood as non-limiting examples. In such examples, as the valvereceives the signal indicative of a position to adjust to, the valve maybegin turning to the indicated position. Such an operation may taketime, depending on the valve used. To ensure proper operation andprevent damage (e.g., damage to the high-pressure heat exchanger 250,such as when pressure of the wellhead fluid exceeds a pressure rating ofthe high-pressure heat exchanger 250), the valve may be configured toclose in a specified period of time while high-pressure fluid flowstherethrough. Such a configuration may be based on a torque value of thevalve, e.g., a valve with a higher torque value may close faster thanthat of a control valve with a lower torque value. Such a specifiedperiod of time may be 5 seconds to 10 seconds, 5 seconds to 15 seconds,5 seconds to 20 seconds, 10 seconds to 15 seconds, 10 seconds to 20seconds, or 15 seconds to 20 seconds. For example, if a wellhead fluidflow exceeds a pressure of 15,000 PSI, the first heat exchanger valve208 may close within 5 seconds of the pressure sensor 214 indicating thepressure exceeding 15,000 PSI. In other embodiments, the valves mayeither fully open or fully close, rather than open to positions inbetween. In yet other examples, the valves may be manually or physicallyopened by operators or technicians on-site.

As illustrated in FIG. 2A, pressure sensors 204, 212, 214, 222, 207and/or temperature sensors 206, 216, 218, 226, 218 may be disposed atvarious points on or along different pipes, equipment, apparatuses,and/or devices at the well. Each sensor may provide information toadjust and/or control various aspects of the wellhead fluid flow. Forexample, pressure sensors 204, 212 may provide pressure measurements todetermine whether a flow of wellhead fluid is not impeded in relation tohydrocarbon production targets. Pressure sensors 214, 220 may providemeasurements to ensure that the flow of wellhead fluid through thehigh-pressure heat exchanger 250 is sufficient to facilitate heattransfer from the wellhead fluid to a working fluid in a ORC loop 221and/or that the pressure within the high-pressure heat exchanger 250does not exceed a pressure rating of the high-pressure heat exchanger250. In another example, temperature sensor 206 may provide data tocontrol flow of the wellhead fluid. For example, if the flow of wellheadfluid is at a temperature sufficient to cause the working fluid toexhibit a vaporous phase change, then the first heat exchanger valve 208and second heat exchanger valve 222 may be opened. Further, temperaturesensors 216, 218, 226, 248 may provide measurements to ensure that thetemperatures within the heat exchanger, of the flow of wellhead fluid,and of the flow of working fluid, are above the thresholds or within arange of thresholds, e.g., above a vaporous phase change threshold. Forexample, rather than or in addition to using temperature of the wellheadfluid as measured by temperature sensor 206, the temperature of theworking fluid as measured by temperature sensor 226 may be utilized todetermine whether to maintain an open position of an already open firstheat exchanger valve 208. In such examples, the first heat exchangervalve 208 may initially be fully or partially open, e.g., prior to flowof the wellhead fluid.

In another embodiment, in addition to the first heat exchanger valve 208and second heat exchanger valve 222, the well 200 may include a firstORC unit valve 295 and a second ORC unit valve 296. Such ORC unit valves295, 296 may be utilized to control flow of working fluid flowing intothe ORC unit 203. Further the ORC unit valves 295, 296 may be utilizedwhen more than one high-pressure heat exchanger 250 corresponding to oneor more wellheads are connected to the ORC unit 203. The ORC unit valves295, 296 may be utilized to optimize or to enable the ORC unit 203 tomeet a preselected electrical power output threshold via the flow ofworking fluid from one or more high-pressure heat exchangers into theORC unit 203, as will be understood by a person skilled in the art. Theflow of working fluid may be adjusted to ensure that the ORC unit 203produces an amount of electrical power greater than or equal to apreselected electrical power output threshold, based on various factorsor operating conditions (e.g., temperature of wellhead fluid flow,temperature of working fluid flow, electrical output 236 of the ORC unit203, electrical rating of the ORC unit 203, flow and/or pressure of thewellhead fluid, and/or flow and/or pressure of the working fluid). Insome examples, the ORC unit valves 295, 296 may initially be fully openor at least partially open and as various factors or operatingconditions are determined, then the ORC unit valves 295, 296 for one ormore heat exchangers may be adjusted to enable the ORC unit 203 to meeta preselected electrical power output threshold, as will be understoodby a person skilled in the art. The preselected electrical power outputthreshold may be set by a user or may be a predefined value generated bya controller (e.g., controller 272) based on various factors. Thevarious factors may include an ORC unit electrical power rating oroutput rating or maximum potential temperature of the wellhead fluidand/or working fluid.

As shown, several pairs of sensors may be located adjacent to oneanother. In other examples, those positions, for example, the pressuresensor's 204 and the temperature sensor's 206 location, may be reversed.In yet another example, each one of the sensors may provide measurementsfor multiple aspects of the wellhead fluid, e.g., one sensor to providea combination of flow, pressure, temperature, composition (e.g., amountof components in the wellhead fluid, such as water, hydrocarbons, otherchemicals, proppant, etc.), density, or other aspect of the wellheadfluid or working fluid. Each sensor described above may be integrated inor within the pipes or conduits of each device or component, clamped onor over pipes or conduits, and or disposed in other ways, as will beunderstood by those skilled in the art. Further, the determinations,adjustments, and/or other operations described above may occur or may beperformed by or in a controller.

As noted, a high-pressure heat exchanger 250 may be disposed, placed, orinstalled at a well. The high-pressure heat exchanger 250 may bedisposed nearby or at a distance from the wellhead 202. Thehigh-pressure heat exchanger 250 may be a modular and/or mobileapparatus. In such examples, the high-pressure heat exchanger 250 may bebrought or moved to a well or site (e.g., via a vehicle, such as atruck), placed at the well or site during hydrocarbon production, andthen moved to another well or site at the end of hydrocarbon production.The high-pressure heat exchanger 250 may be disposed on a skid, atrailer, a flatbed truck, inside a geothermal generator unit, or insidean ORC unit 203. Once brought to a well or site, the high-pressure heatexchanger 250 may be secured to the surface at the well. Thehigh-pressure heat exchanger 250 may be configured to withstandpressures in excess of about 5,000 PSI, about 10,000 PSI, about 15,000PSI, and/or greater. In an example, the high-pressure heat exchanger 250may be a high-pressure shell and tube heat exchanger, a spiral plate orcoil heat exchanger, a heliflow heat exchanger, or other heat exchangerconfigured to withstand high pressures. In another example, portions ofthe high-pressure heat exchanger 250 may be configured to withstandhigh-pressures. For example, if a shell and tube heat exchanger isutilized, the shell and/or tubes may be configured to withstandhigh-pressures.

In another embodiment, at least one fluidic path of the high-pressureheat exchanger 250 may be coated or otherwise configured to reduce orprevent corrosion. In such examples, a wellhead fluid may be corrosive.To prevent damage to the high-pressure heat exchanger 250 over a periodof time, the fluid path for the wellhead fluid may be configured towithstand such corrosion by including a permanent, semi-permanent, ortemporary anti-corrosive coating, an injection point for anti-corrosivechemical additive injections, and/or some combination thereof. Further,at least one fluid path of the high-pressure heat exchanger 250 may becomprised of an anti-corrosive material, e.g., anti-corrosive metals orpolymers. As noted, the wellhead fluid may flow into the high-pressureheat exchanger 250 at a high pressure. As the high-pressure heatexchanger 250 may operate at high pressure, the high-pressure heatexchange may include pressure relief valves to prevent failures ifpressure within the high-pressure heat exchanger 250 were to exceed thepressure rating of the high-pressure heat exchanger 250. Over time,wellhead fluid flowing through the high-pressure heat exchanger 250 maycause a buildup of deposits or scaling. To prevent scaling and/or otherrelated issues, the high-pressure heat exchanger 250 may be injectedwith scaling inhibitors or other chemicals or may include vibration orradio frequency induction devices.

Once the high-pressure heat exchanger 250 facilitates heat transfer fromthe wellhead fluid to the working fluid, the working fluid maypartially, substantially, or completely change phases from a liquid to avapor, vaporous state, gas, or gaseous state. The vapor or gas may flowto the ORC unit 203 causing an expander to rotate. The rotation maycause a generator to generate electricity, as will be further describedand as will be understood by those skilled in the art. The generatedelectricity may be provided as an electrical output 236. The electricitygenerated may be provided to in-field equipment, energy storage devices,equipment at other wells, or to a grid power structure. The workingfluid in the high-pressure heat exchanger may be a working fluid tocarry heat. Further, the working fluid of the high-pressure heatexchanger 250 may or may not exhibit a vaporous phase change. Theworking fluid may carry heat to another heat exchanger 205 of the ORCunit 203. As such, heat may be transferred from the wellhead fluid tothe working fluid of the high-pressure heat exchanger 250 and heat maybe transferred from the working fluid of the high-pressure heatexchanger 250 to the working fluid of the ORC unit 203.

In an example, the working fluid may be a fluid with a low boiling pointand/or high condensation point. In other words, a working fluid may boilat lower than typical temperatures, while condensing at higher thantypical temperatures. The working fluid may be an organic working fluid.The working fluid may be one or more of pentafluoropropane, carbondioxide, ammonia and water mixtures, tetrafluoroethane, isobutene,propane, pentane, perfluorocarbons, other hydrocarbons, a zeotropicmixture of pentafluoropentane and cyclopentane, other zeotropicmixtures, and/or other fluids or fluid mixtures. The working fluid'sboiling point and condensation point may be different depending on thepressure within the ORC loop 221, e.g., the higher the pressure, thelower the boiling point.

FIG. 2B illustrates an embodiment of the internal components of an ORCunit 203. FIG. 2B further illustrates several of the same components,equipment, or devices as FIG. 2A illustrates. As such, the numbers usedto label FIG. 2B may be the same as those used in 2A, as those numbercorrespond to the same component. The ORC unit 203 as noted may be amodular or mobile unit. As power demand increases, additional ORC units203 may be added, installed, disposed, or placed at the well. The ORCunits 203 may stack, connect, or integrate with each other ORC unit. Inan example, the ORC unit 203 may be a modular single-pass ORC unit.

An ORC unit 203 may include a heat exchanger 205 or heater. Connectionsto the heat exchanger 205 or heater may pass through the exterior of theORC unit 203. Thus, as an ORC unit 203 is brought or shipped to a wellor other location, a user, technician, service person, or other personmay connect pipes or hoses from a working fluid heat source (e.g., thehigh-pressure heat exchanger 250) to the connections on the ORC unit203, allowing a heat source to facilitate phase change of a secondworking fluid in the ORC unit 203. In such examples, the working fluidflowing through ORC loop 221 may include water or other organic fluidexhibiting a higher vaporous phase change threshold than the workingfluid of the ORC unit 203, to ensure proper heat transfer in heatexchanger 205. Further, the heat exchanger 205 may not be ahigh-pressure heat exchanger. In such examples, the high-pressure heatexchanger 250 allows for utilization of waste heat from high-pressurewellhead fluids. In another embodiment and as will be described, ahigh-pressure heat exchanger 250 may be included in the ORC unit 203.

In yet another embodiment, the high-pressure heat exchanger 250 may beconsidered an intermediary heat exchanger or another intermediary heatexchanger (e.g., intermediary heat exchanger 219) may be disposedbetween the high-pressure heat exchanger 250 and the ORC unit 203 (asillustrated in FIG. 2C and described below). The working fluid flowingthrough the high-pressure heat exchanger 250 may be sufficient to heatanother working fluid of the ORC unit 203. The working fluid of such anintermediary heat exchanger may not physically flow through any of theequipment in the ORC unit 203, except for heat exchanger 205, therebytransferring heat from the working fluid in ORC loop 221 to an ORCworking fluid in a loop defined by the fluid path through the heatexchanger 205, condenser 211, expander 232, working fluid reservoir 298,and/or pump 244.

The ORC unit 203 may further include pressure sensors 228, 238, 246 andtemperature sensors 230, 240 to determine whether sufficient, efficient,and/or optimal heat transfer is occurring in the heat exchanger 205. Asensor or meter may further monitor electrical power produced via theexpander 232 and generator 234. Further, the ORC unit 203 may include acondenser or heat sink 211 to transfer heat from the second workingfluid or working fluid of the ORC unit 203. In other words, thecondenser or heat sink 211 may cool the second working fluid or workingfluid of the ORC unit 203 causing the second working fluid or workingfluid of the ORC unit 203 to condense or change phases from vapor toliquid. The ORC unit 203 may also include a working fluid reservoir 298to store an amount of working fluid, e.g., in a liquid state, to ensurecontinuous operation of the ORC unit 203. The liquid state workingfluid, whether from the working fluid reservoir 298 or directly form thecondenser/heat sink 211, may be pumped, via pump 244, back to the heatexchanger 205. Further, the pressure prior to and after pumping, e.g.,as measured by the pressure sensors 238, 246, may be monitored to ensurethat the working fluid remains at a ORC unit or working fluid looppressure rating.

As illustrated in FIG. 2C, the well may include an intermediary heatexchanger 219. In such examples, an ORC unit 203 may not be configuredfor high-pressure heat exchange. As such, an intermediary heat exchanger219 may be disposed nearby the high-pressure heat exchanger 250, nearbythe ORC unit 203, or disposed at some other point in between toalleviate such issues. The intermediary heat exchanger 219 may include aworking fluid, also referred to as an intermediary working fluid, toflow through the intermediary loop 223. The intermediary fluid mayinclude water, a water and glycol mixture, or other organic fluidexhibiting a higher vaporous phase change threshold than the workingfluid of the ORC unit 203. In an embodiment, the intermediary heatexchanger 219 may include sensors, meters, transducers and/or otherdevices at various positions throughout to determine characteristic offluids flowing therein, similar to that of the high-pressure heatexchanger 250.

As illustrated in FIG. 2D, rather than utilizing an ORC unit 203 thatmay not withstand high pressure, a high-pressure ORC unit or an ORC unitwith integrated high-pressure heat exchanger 250 may be utilized forgeothermal power generation. In such examples, the components,equipment, and devices may be similar to those described above. Inanother example, such a system, as illustrated in FIG. 2D, may include aheat sink 236 utilizing a cooled flow of wellhead fluid to cool the flowof working fluid. In such examples, as the flow of wellhead fluid passesthrough a choke valve 252, the pressure of the flow of wellhead fluidmay be reduced, e.g., for example, from about 15,000 PSI to about 1,500PSI, from about 15,000 PSI to about 200 PSI, from about 15,000 PSI toabout 100 PSI, about 15,000 PSI to about 50 PSI or lower, from about10,000 PSI to about 200 PSI or lower, from about 5,000 PSI to about 200PSI or lower, or from 15,000 PSI to lower than 200 PSI. In suchexamples, the temperature from a point prior to the choke valve 252 andafter the choke valve 252, e.g., a temperature differential, may beabout 100 degrees Celsius, about 75 degrees Celsius, about 50 degreesCelsius, about 40 degrees Celsius, about 30 degrees Celsius, and lower.For example, the temperature of the wellhead fluid prior to the chokevalve 252 may be about 50 degrees and higher, while, after passingthrough the choke valve 252, the temperature, as measured by thetemperature sensor 259, may be about 30 degrees Celsius, about 25degrees Celsius, about 20 degrees Celsius, to about 0 degrees Celsius.

The system may include, as noted, a temperature sensor 259 and pressuresensor 257 to determine the temperature of the wellhead fluid after thechoke valve 252. The system may include temperature sensor 240 todetermine the temperature of the working fluid or ORC fluid exiting theheat sink 236 and temperature sensor 238 to determine the temperature ofthe working fluid or ORC fluid entering the heat sink 236. The pressureand/or temperature of the wellhead fluid may be used to determinewhether the heat sink 236 may be utilized based on pressure rating ofthe heat sink 236 and/or a liquid phase change threshold of the workingfluid. In other words, if the flow of wellhead fluid is at a temperaturesufficient to cool the working fluid and/or below a pressure rating ofthe heat sink 236, the heat sink valve 254 may open to allow wellheadfluid to flow through the heat sink 236 to facilitate cooling of theworking fluid. In another embodiment, the heat sink valve 254 mayinitially be fully or partially open. The temperature of the workingfluid or ORC fluid may be measured as the fluid enters the heat sink 236and exits the heat sink 236. If the temperature differential indicatesthat there is no change or an increase in temperature, based on thetemperature of the working fluid or ORC fluid entering the heat sink 236and then leaving the heat sink 236, then the heat sink valve 254 may beclosed. Temperature sensors 238, 240, 256, 262, and pressure sensors258, 260 may be disposed within the heat sink 236 to ensure that thetemperature of the wellhead fluid is suitable for cooling the workingfluid and that the pressure of wellhead fluid does not exceed thepressure rating of the heat sink 236.

FIG. 2D also illustrates two flow meters 277, 279 disposed prior to thefirst wellhead fluid valve 210 and first heat exchanger valve 208. Suchflow meters may measure the flow of the wellhead fluid at the pointwhere the meter is disposed. Utilizing flow measurements may allow forfine-tuning or adjustment of the open percentage or position of thevalves included in the system. Such fine-tuning or adjustment may ensurethat the production of hydrocarbons at the well is not impeded by theuse of the high-pressure heat exchanger. Other flow meters may bedisposed at various other points of the system, e.g., after the firstwellhead fluid valve 210, prior to or after the choke valve 252, at apoint after the heat sink 236, and/or at various other points in thesystem. As stated, these flow meter may be utilized to ensure properflow wellhead fluid throughout the system. In an example, the sensorsand/or meters disposed throughout the system may be temperature sensors,densitometers, density measuring sensors, pressure transducers, pressuresensors, flow meters, mass flow meters, Coriolis meters, spectrometer,other measurement sensors to determine a temperature, pressure, flow,composition, density, or other variable as will be understood by thoseskilled in the art, or some combination thereof. Further, the sensorsand/or meters may be in fluid communication with a liquid to measure thetemperature, pressure, or flow or may indirectly measure flow (e.g., anultrasonic sensor). In other words, the sensors or meters may be aclamp-on device to measure flow indirectly (such as via ultrasoundpassed through the pipe to the liquid).

As illustrated in FIG. 2E, a controller 272 may be included at the well.The controller 272 may be utilized in any of the previous or followingdrawings. The controller 272 may include one or more controllers, asupervisory controller, and/or a master controller. The controller 272may connect to all the equipment and devices shown, including additionalequipment and devices not shown, and may transmit control signals,receive or request data or measurements, control pumps, monitorelectricity generated, among other things (see 274). The controller 272may, in another example, control a subset of the components shown. Inanother example, a controller may be included in an ORC unit (see 203 inFIGS. 2A through 2C). The controller 272 may connect to and control thecontroller in the ORC unit 203. The controller 272 may transmit signalsto the various control valves to open and close the valves by determinedamounts or percentages or fully open or close the valves. The controller272 may further determine, via a meter or other device or sensor, anamount of electrical power generated or being generated by the generator234 or ORC unit 203.

As illustrated in FIG. 2F, the system may include another heat sink 241,in the case that the cooling offered by the flow of wellhead fluid inheat sink 236 is not sufficient. In an example, the heat sink 241 may bea fin fan cooler, a heat exchanger, a condenser, any other type of heatsink, a sing-pass parallel flow heat exchanger, a 2-pass crossflow heatexchanger, a 2-pass countercurrent heat exchanger, or other type ofapparatus. As illustrated in FIG. 2G, the system may include aregenerator 290. In such examples, the working fluid may flow through afirst fluid path of the regenerator 290. After the working fluid iscooled by a primary heat sink (e.g., heat sink 236), the working fluidmay flow back through another fluid path of the regenerator 290. Assuch, the heat from the first fluid path may pre-heat the working fluid,while the second fluid path may offer some level of cooling to theworking fluid.

As illustrated in FIG. 2H, the system may include a gas expander 291. Inan example, the gas expander 291 may be a turbine expander, positivedisplacement expander, scroll expander, screw expander, twin-screwexpander, vane expander, piston expander, other volumetric expander,and/or any other expander suitable for an ORC operation or cycle. Forexample, and as illustrated, the gas expander 291 may be a turbineexpander. As gas flows through the turbine expander, a rotor 293connected to the turbine expander may begin to turn, spin, or rotate.The rotor 293 may include an end with windings. The end with windingsmay correspond to a stator 294 including windings and a magnetic field.As the rotor 293 spins within the stator 294, electricity may begenerated. Other generators may be utilized, as will be understood bythose skilled in the art. The generator 293 may produce DC power, ACpower, single phase power, or three phase power.

FIG. 3A and FIG. 3B are block diagrams illustrating other novelimplementations of a geothermal power generation enabled well to provideelectrical power to one or more of in-field equipment, equipment atother wells, energy storage devices, and the grid power structure,according to one or more embodiment of the disclosure. FIGS. 3A and 3Bmay represent a side-view perspective block diagram of a well and thecomponents at the well. In an example, wellhead fluid may flow fromunderground 304. The wellhead fluid flow 308 may include hydrocarbons ora mixture of hydrocarbons and other fluids, e.g., water, chemicals,fluids leftover from fracturing operations, other residuals, and/orother fluids as will be understood by those skilled in the art. Thewellhead fluid may flow from a wellbore.

As the wellhead fluid flows from the wellhead 306, the wellhead fluidmay flow to the high-pressure heat exchanger, through a bypass pipe,and/or a combination thereof based on various factors orcharacteristics, e.g., wellhead fluid temperature and/or pressure and/orworking fluid temperature. For example, if the wellhead fluid flow 308is above a vaporous phase change threshold for a working fluid flow 310,then valve 332 may open, at least partially, to allow the wellhead fluidflow to the high pressure heat exchanger 312. In such examples, thewellhead fluid may continue to flow through the primary or bypasswellhead fluid pipe. As such, valve 330 may remain open, whethercompletely or at a certain percentage. From the high-pressure heatexchanger 312, the wellhead fluid may flow back to the primary or bypasswellhead fluid pipe, to a condenser 316 or other cooling apparatus,and/or a combination thereof. If the wellhead fluid is at a temperatureto provide cooling to the working fluid flow 310, then valve 336 mayopen to allow wellhead fluid to flow therethrough. In such examples, thevalve 334 may close to prevent wellhead fluid from flowing back. If thewellhead fluid is not at a temperature to allow for cooling of theworking fluid flow 310, then valve 336 may close or remained closed andvalve 334 may open or remain open. From the condenser 316 or the primaryor bypass wellhead fluid pipe, the wellhead fluid may flow to in-fieldequipment 316, storage tanks, and/or other processing equipment at thewell. The valves described above may be controlled via controller 320.

In another embodiment, rather than basing the opening and closing ofvalve 332 and/or valve 336 on wellhead fluid flow 308 temperature, thevalve 332 and/or valve 336 may be opened or closed based on thetemperature of the working fluid flow 310. For example, prior toactivating the wellhead 306 (e.g., allowing wellhead fluid to flow orpumping wellhead fluid from the wellhead 306), valve 332 may be open,fully or partially. As the wellhead fluid flows through thehigh-pressure heat exchanger 312, the temperature of the working fluidflow 310 may be measured. Based on the working fluid flow 310temperature, taken at continuously or at periodic intervals, and after aspecified period of time, if the working fluid flow 310 does not reach avaporous phase change temperature, then valve 332 may be closed.Further, such operations may be performed in conjunction with measuringwellhead fluid flow 308 and opening or closing valve 332 based on suchmeasurements.

The wellhead fluid flowing through the high-pressure heat exchanger 312may be at a temperature to facilitate heat transfer to a working fluidflow 310. The working fluid may further flow, as a vaporous stateworking fluid flow to an ORC expander/generator 314. The vaporous stateworking fluid may cause the ORC expander/generator 314 to generateelectrical power to be utilized at equipment at the well (e.g., in-fieldequipment), energy storage device, or a grid power structure (via atransformer and power lines). The working fluid may then flow to acondenser 316 or other cooling apparatus. The condenser 316 or othercooling apparatus may facilitate cooling of the working fluid flow 310via the wellhead fluid flow, air, another liquid, and/or other types ofheat sinks or heat exchangers. The liquid state working fluid may thenflow back to the high-pressure heat exchanger 312.

In another embodiment, the high-pressure heat exchanger 312 may connectto an ORC unit/module 340 or one or more ORC units or modules. Thenumber of ORC units/modules may scale based on power to be utilized byin-field equipment, the amount or potential capacity of electricitygeneration at the well, and/or other factors. After production ofhydrocarbons begins, additional ORC units/modules may be added at thewell or existing ORC units/modules may be removed from the well.

FIG. 4A and FIG. 4B are simplified diagrams illustrating a controlsystem for managing the geothermal power production at a well, accordingto one or more embodiment of the disclosure. A master controller 402 maymanage the operations of geothermal power generation at a wellheadduring hydrocarbon production. The master controller 402 may be one ormore controllers, a supervisory controller, programmable logiccontroller (PLC), a computing device (such as a laptop, desktopcomputing device, and/or a server), an edge server, a cloud basedcomputing device, and/or other suitable devices. The master controller402 may be located at or near the well. The master controller 402 may belocated remote from the well. The master controller 402, as noted, maybe more than one controller. In such cases, the master controller 402may be located near or at various wells and/or at other off-sitelocations. The master controller 402 may include a processor 404, or oneor more processors, and memory 406. The memory 406 may includeinstructions. In an example, the memory 406 may be a non-transitorymachine-readable storage medium. As used herein, a “non-transitorymachine-readable storage medium” may be any electronic, magnetic,optical, or other physical storage apparatus to contain or storeinformation such as executable instructions, data, and the like. Forexample, any machine-readable storage medium described herein may be anyof random access memory (RAM), volatile memory, non-volatile memory,flash memory, a storage drive (e.g., hard drive), a solid state drive,any type of storage disc, and the like, or a combination thereof. Asnoted, the memory 406 may store or include instructions executable bythe processor 404. As used herein, a “processor” may include, forexample one processor or multiple processors included in a single deviceor distributed across multiple computing devices. The processor may beat least one of a central processing unit (CPU), a semiconductor-basedmicroprocessor, a graphics processing unit (GPU), a field-programmablegate array (FPGA) to retrieve and execute instructions, a real timeprocessor (RTP), other electronic circuitry suitable for the retrievaland execution instructions stored on a machine-readable storage medium,or a combination thereof.

As used herein, “signal communication” refers to electric communicationsuch as hard wiring two components together or wireless communicationfor remote monitoring and control/operation, as understood by thoseskilled in the art. For example, wireless communication may be Wi-Fi®,Bluetooth®, ZigBee, cellular wireless communication, satellitecommunication, or forms of near field communications. In addition,signal communication may include one or more intermediate controllers orrelays disposed between elements that are in signal communication withone another.

The master controller 402 may include instructions 408 to measuretemperature at various points or locations of the system (e.g., asillustrated in, for example, FIG. 2E). For example, temperature may bemeasured at a wellhead fluid temperature sensor 1 416, heat exchangertemperature sensors 418, wellhead fluid temperature sensor 2 420,condenser temperature sensors 422, and/or at various other points in thesystem 400. Other characteristics may be measured as well, such as flow,density, pressure, composition, or other characteristics related to thewellhead fluid and/or working fluid.

Utilizing the characteristics noted above, the master controller 402 maycontrol various aspects of the system 400. For example, the mastercontroller 402 may include flow control adjustment instructions 412. Thesystem 400 may include one or more valves placed in various locations(For example, but not limited to, FIGS. 2A through 2H). Valves of thesystem 400 may include a wellhead fluid valve 1 426, heat exchangervalves 428, wellhead fluid valve 2 430, and condenser valves 432. Asnoted other valves may be included in the system and controlled by themaster controller 402. The valves may operate to adjust flow based on anumber of factors. Such factors may include temperature of a wellheadfluid, flow rate of the wellhead fluid, temperature of the workingfluid, flow rate of the working fluid, pressure of the wellhead fluid atvarious points in the system, pressure of the working fluid at variouspoints in the system, and/or some combination thereof.

In an example, the system 400 may include a user interface 436, e.g.,such as a monitor, display, computing device, smartphones, tablets, andother similar devices as will be understood by those skilled in the art.A user may view data, enter thresholds or limits, monitor status of theequipment, and perform other various tasks in relation to the equipmentat the well. For example, a specific flow rate may be set forhydrocarbon production. As a wellhead begins producing hydrocarbons(e.g., wellhead fluids begin flowing from a wellhead), the mastercontroller 402 may monitor flow rate and compare the flow rate to thethreshold either set by a user or pre-set in the master controller 402.If the master controller 402 determines that the heat exchanger valves428 (e.g., via flow control adjustment instructions 412) should be openor are open and that the flow of wellhead fluid is higher or lower thanthe threshold, the master controller 402 may adjust the appropriatevalves, e.g., wellhead fluid valve 426 and/or heat exchanger valves 428.The valve associated with the primary or bypass wellhead fluid pipe,e.g., wellhead fluid valve 426, may open or close by varying degreesbased on such determinations.

In another example, the master controller 402 may include instructions410 to control a pump for the ORC unit, e.g., working fluid pump 424. Ifheat exchanger valves 428 and condenser valves 432 are closed, themaster controller 402 may transmit a signal to shut down or ceaseoperation of the working fluid pump 424, if the working fluid pump 424is operating. The master controller 402 may further transmit a signal,based on the heat exchanger valves 428 being open, to initiate or startoperations of the working fluid pump 424. The working fluid pump 424 maybe a fixed pressure pump or a variable frequency pump. The mastercontroller 402 may further include instructions 414 to monitor the poweroutput from an ORC unit or from expanders/generators 434 (e.g.,expander/generator A 434A, expander/generator B 434B, and/or up toexpander/generator N 434N). If the system 400 utilizes ORC units, themaster controller 402 may determine the electrical power generated oroutput based on an output from, for example, ORC unit controller A 438A,ORC unit controller B 438B, and/or up to ORC unit controller N 438N. Ifthe power output drops to an un-economical or unsustainable level orelectrical power generation ceases completely while the heat exchangervalves 428 are open, the master controller 402 may transmit signals toclose the heat exchanger valves 428. In another example, the mastercontroller 402 may monitor electrical power output from other wells. Themaster controller 402 may monitor or meter the amount of electricalpower being utilized at each of the wells and/or the amount ofelectrical power being generated at each of the wells. If an excess ofelectrical power exists, the master controller 402 may transmit signalscausing the excess energy at any particular well to be stored in energystorage devices, transmitted to the grid, and/or transmitted to anotherwell. If a deficit of electrical power exists, the master controller 402may transmit a signal causing other wells to transmit electrical powerto the well experiencing an electrical power deficit. In anotherexample, the metered electrical power may be utilized for commercialtrade, to determine a cost of the electricity generated, and/or for usein determining emissions or emission reductions through use of analternate energy source (e.g., geothermal power).

In another example, the master controller 402 may include instructionsto maximize energy output from an ORC unit. In such examples, the ORCunit may be connected to a plurality of high-pressure heat exchangers.Further, each of the high-pressure heat exchangers may connect to one ormore wellheads. As a wellhead produces a wellhead fluid, the pressureand temperature of the wellhead fluid may vary, over time, as well asbased on the location of the wellhead. The master controller 402 maydetermine the temperature of the wellhead fluid at each high-pressureheat exchanger and/or the temperature of the working fluid in eachhigh-pressure heat exchanger. Based on these determinations, the mastercontroller 402 may open/close valves associated with one or moreparticular high-pressure heat exchangers to ensure the most efficientheat transfer. Further, the master controller 402 may determine theamount of electrical power output from the ORC unit. Based on a powerrating of the ORC unit (e.g., the maximum power output the ORC unit isable to produce) and/or the amount of electrical power output from theORC unit, the master controller 402 may adjust valves associated withthe one or more particular high-pressure heat exchangers to therebyincrease electrical power output. Additional ORC units may be utilizedand electrical power output for each may be optimized or efficientlygenerated. The master controller 402 may determine, for each ORC unit,the optimal amount or efficient amount of heated working fluid flowingfrom each high-pressure heat exchanger to ensure the highest amount ofelectrical power possible is generated per ORC unit or that each ORCunit meets a preselected electrical power output threshold. In suchexamples, each ORC unit may be connected to each high-pressure heatexchanger and the master controller 402 may determine which set ofvalves to open/close based on such an optimization or electrical poweroutput threshold.

In another example, the master controller 402 may include failoverinstructions or instructions to be executed to effectively reduce orprevent risk. The failover instructions may execute in the event of ORCunit and/or high-pressure heat exchanger failure or if an ORC unitand/or high-pressure heat exchanger experiences an issue requiringmaintenance. For example, the ORC unit and/or high-pressure heatexchanger may have various sensors or meters. Such sensors or meters,when providing measurement to the master controller 402, may indicate afailure in the ORC unit and/or high-pressure heat exchanger. In anotherexample, the master controller 402 may include pre-determined parametersthat indicate failures. If the master controller 402 receives suchindications, the master controller 402 may open, if not already open,the wellhead fluid valve 1 426 and wellhead fluid valve 2 430. After thewellhead fluid valve 1 426 and wellhead fluid valve 2 430 are opened,the master controller 402 may close the heat exchanger valves 428, thecondenser valves 432, or any other valve associated with the flow offluid to the ORC unit and/or high-pressure heat exchanger. In suchexamples, the master controller 402 may prevent further use of the ORCunit and/or high-pressure heat exchanger until the issue or failureindicated is resolved. Such a resolution may be indicated by a user viathe user interface 436 or based on measurements from sensors and/ormeters.

In another example, the master controller 402 may, as noted, determinean amount of electrical power output by an ORC unit. The mastercontroller 402 may additionally determine different characteristics ofthe electrical power output. For example, the master controller 402 maymonitor the output voltage and frequency. Further, the master controller402 may include pre-set or predetermined thresholds, limits, orparameters in relation to the monitored characteristics of theelectrical power output. Further still, the master controller 402 mayconnect to a breaker or switchgear. In the event that the mastercontroller 402 detects that an ORC unit exceeds any of the thresholds,limits, and/or parameters, the master controller 402 may transmit asignal to the breaker or switchgear to break the circuit (e.g., the flowof electricity from the ORC unit to a source) and may shut down the ORCunit (e.g., closing valves preventing further flow to the ORC unit, asdescribed above).

FIG. 5 is a flow diagram of geothermal power generation in which, when awellhead fluid is at or above a vaporous phase change temperaturethreshold, heat exchanger valves may be opened to allow wellhead fluidto flow therethrough, thereby facilitating heating of a working fluidfor use in a ORC unit, according to one or more embodiment of thedisclosure. The method is detailed with reference to the mastercontroller 402 and system 400 of FIGS. 4A and 4B. Unless otherwisespecified, the actions of method 500 may be completed within the mastercontroller 402. Specifically, method 500 may be included in one or moreprograms, protocols, or instructions loaded into the memory of themaster controller 402 and executed on the processor or one or moreprocessors of the master controller 402. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

At block 502, the master controller 402 may determine whether thewellhead is active. Such a determination may be made based on sensorslocated at or near the wellhead, e.g., a pressure sensor indicating apressure or a flow meter indicating a flow of a wellhead fluid orhydrocarbon stream from the wellhead. In other examples, a user mayindicate, via the user interface 436, that the wellhead is active. Ifthe wellhead is not active, the master controller 402 may wait for aspecified period of time and make such a determination after the periodof time. In an example, the master controller 402 may continuously checkfor wellhead activity.

At block 504, in response to wellhead activity or during hydrocarbonproduction, the master controller 402 may determine a wellhead fluidtemperature. The wellhead fluid temperature may be measured by awellhead fluid temperature sensor 1 416 disposed at or near thewellhead. The wellhead fluid temperature sensor 1 416 may be disposed onor in a pipe. In an example, various other temperature sensors may bedisposed at other points in the system 400, e.g., heat exchangertemperature sensor 418, wellhead fluid temperature sensor 2 420,condenser temperature sensor 422, and/or other temperature sensors. Thetemperature measurements provided by such sensors may be utilized by themaster controller 402 to determine which valves to open or close.

At block 506, the master controller 402 may determine whether thewellhead fluid is at or above a vaporous phase change temperaturethreshold of a working fluid. In such examples, the vaporous phasechange temperature may be based on the working fluid of the ORC unit.For example, for pentafluoropropane the vaporous phase changetemperature or boiling point may be 15.14 degrees Celsius. In anotherexample, or factors may be taken into account when determining whetherto open heat exchanger valves 428. For example, whether the pressure iswithin operating range of a high-pressure heat exchanger, whether theflow rate at a primary or bypass pipeline is sufficient to preventimpedance of hydrocarbon production, whether power generation costs areoffset by power generation needs, among other factors.

At block 508, if the wellhead fluid is at or above the vaporous phasechange temperature, the master controller 402 may transmit a signal toheat exchanger valves 428 to open to a specified degree. In an example,the heat exchanger valves 428 may be may be fully opened or partiallyopened. The degree to which the heat exchanger valves 428 opens maydepend on the temperature of the wellhead fluid, the flow rate of thewellhead fluid, and/or the pressure of the wellhead fluid.

At block 510, the master controller 402 may close wellhead fluid valves(e.g., wellhead fluid valve 1 426) to divert a portion of the flow ofwellhead fluids to the high-pressure heat exchanger. The wellhead fluidvalves (e.g., wellhead fluid valve 1 426) may close partially orcompletely, depending on various factors, such as heat exchanger flowcapacity, current flow rate, current pressure, current temperature,among other factors. Once the wellhead fluid valves (e.g., wellheadfluid valve 1 426) are closed, at block 512, a working fluid pump 424 ofthe ORC unit may begin pumping the working fluid through the ORC loop.At block 514, the master controller 402 may determine whetherelectricity is being generated. If not, the master controller 402 maycheck if the wellhead is still active and, if the wellhead is stillactive, the master controller 402 may adjust the valves (e.g., wellheadfluid valve 1 426 and heat exchanger valves 428) as appropriate (e.g.,increasing flow through the heat exchanger to facilitate an increase inheat transfer).

At block 516, if the wellhead fluid is lower than the vaporous phasechange temperature, the master controller 402 may open or check if thewellhead fluid valves (e.g., wellhead fluid valve 1 426) are open.Further, the wellhead fluid valves may already be open to a degree and,at block 516, may open further or fully open, depending on desiredwellhead fluid flow. In an example, the wellhead fluid valve (e.g.,wellhead fluid valve 1 426) may be used, with or without a separatechoke valve, to choke or partially choke the wellhead fluid flow.Further, once the wellhead fluid valves are open, at block 518, themaster controller 402 may close the heat exchanger valves 428 fully orpartially in some cases.

FIG. 6 is another flow diagram of geothermal power generation in which,when a wellhead fluid is at or above a vaporous phase changetemperature, heat exchanger valves may be opened to allow wellhead fluidto flow therethrough, thereby facilitating heating of a working fluidfor use in a ORC unit, according to one or more embodiment of thedisclosure. The method is detailed with reference to the mastercontroller 402 and system 400 of FIGS. 4A and 4B. Unless otherwisespecified, the actions of method 600 may be completed within the mastercontroller 402. Specifically, method 600 may be included in one or moreprograms, protocols, or instructions loaded into the memory of themaster controller 402 and executed on the processor or one or moreprocessors of the master controller 402. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

Blocks 602 through 610 correspond to blocks 502 through 610, asdescribed above. Once it has been determined that the heat exchangervalves 428 should be open and after the heat exchanger valves 428 open,wellhead fluid may flow through the heat exchanger and/or the primary orbypass wellhead fluid pipe to a choke valve. The choke valve may reducethe pressure of the wellhead fluid and, thus, reduce the temperature ofthe wellhead fluid. At block 612, the master controller 402 maydetermine the reduced pressure wellhead fluid temperature at or near acondenser or heat sink valve based on a measurement from the condensertemperature sensors 422. The master controller 402 may, at block 614,determine whether the wellhead fluid is at cool enough temperatures tofacilitate cooling of a working fluid flow. The working fluid may have acondensation point or a temperature at which the working fluid changesphase from a vapor to a liquid. Such a temperature may be utilized asthe threshold for such determinations.

At block 616, if the temperature is cool enough, the master controller402 may open the condenser valves 432, allowing wellhead fluid to flowthrough the condenser or other cooling apparatus. At block 617 themaster controller 402 may transmit a signal to the working fluid pump424 to start or begin pumping working fluid through an ORC loop. Inanother example, at block 619, if the temperature of the working fluidis not cool enough to facilitate cooling of the working fluid to anydegree, the master controller 402 may close the condenser valves 432. Inanother example, the master controller 402 may determine the temperatureof the reduced pressure wellhead fluid flow and whether the temperatureof the reduced pressure wellhead fluid flow, in conjunction with aprimary or secondary cooler, may cool the working fluid to a point. Themaster controller 402, in such examples, may consider the temperature ofthe working fluid entering the condenser and the temperature of thereduced pressure wellhead fluid flow at or near the condenser valve 432.

As noted and described above, the master controller 402 may, at block618, determine whether electric power is generated. In another example,if the wellhead temperature is not high enough to produce geothermalpower, the master controller 402 may, at block 620, open the wellheadfluid valves. At block 622, the master controller 402 may close, if theheat exchanger valves 428 are open, the heat exchanger valves 428.Finally, at block 624, the master controller 402 may close condenservalves 432.

FIG. 7A is a flow diagram of geothermal power generation in which, whena working fluid or ORC fluid is at or above a vaporous phase changetemperature threshold, heat exchanger valves may remain open to allowwellhead fluid to flow therethrough, thereby facilitating heating of theworking fluid or ORC fluid for use in an ORC unit, according to one ormore embodiment of the disclosure. The method is detailed with referenceto the master controller 402 and system 400 of FIGS. 4A and 4B. Unlessotherwise specified, the actions of method 700 may be completed withinthe master controller 402. Specifically, method 700 may be included inone or more programs, protocols, or instructions loaded into the memoryof the master controller 402 and executed on the processor or one ormore processors of the master controller 402. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

At block 702, the master controller 702 may determine whether thewellhead is active. Such a determination may be made based on sensorslocated at or near the wellhead, e.g., a pressure sensor indicating apressure or a flow meter indicating a flow of a wellhead fluid orhydrocarbon stream from the wellhead. In other examples, a user mayindicate, via the user interface 436, that the wellhead is active. Ifthe wellhead is not active, the master controller 402 may wait for aspecified period of time and make such a determination after thespecified period of time. In an example, the master controller 402 maycontinuously check for wellhead activity.

At block 704, in response to wellhead activity or during hydrocarbonproduction, the master controller 402 may open heat exchanger valves428. At block 706, the master controller 402 may close wellhead fluidvalve 1 426, at least partially. At block 708, when the heat exchangervalves 428 is open and wellhead fluid valve 1 426 is fully or partiallyclosed, working fluid or ORC fluid may be pumped through the ORC unit.

At block 710, the master controller 402 may measure the temperature ofthe working fluid or ORC fluid. At block 712, the master controller 402may determine whether the wellhead fluid is at or above a vaporous phasechange temperature threshold. In such examples, the vaporous phasechange may include when the working fluid or ORC fluid changes from aliquid to a vapor or gas. For example, for pentafluoropropane thevaporous phase change temperature or boiling point may be 15.14 degreesCelsius. In another example, other factors may be taken into accountwhen determining whether to maintain an open percentage of the heatexchanger valves 428. For example, whether the pressure is withinoperating range of a high-pressure heat exchanger, whether the flow rateat a primary or bypass pipeline is sufficient to prevent impedance ofhydrocarbon production, whether power generation costs are offset bypower generation needs, among other factors.

At block 712, if the working fluid or ORC fluid is at or above thevaporous phase change temperature, the master controller 402 maydetermine whether electricity is generated at the ORC unit. Ifelectricity is not generated, the master controller 402 may check, atblock 702, whether the wellhead is active and perform the operations ofmethod 700 again.

If the working fluid or ORC fluid, at block 712 is not at a vaporousphase change temperature, then, at block 714, the master controller 402may first determine whether a first specified period of time has lapsed.The first period of time may be period of time of sufficient length todetermine whether or not the working fluid or ORC fluid may reach avaporous phase change state. Such a first specified period of time maybe about an hour or more, two hours, three hours, four hours, or someother length of time during wellhead activity.

If the first specified period of time has not lapsed, at block 716, themaster controller 402 may wait a second specified period of time beforemeasuring the temperature of the working fluid or ORC fluid The secondspecified period of time may be less than the first specified period oftime.

If the first specified period of time has lapsed, then the mastercontroller 402 may have determined that, based on the temperature of theworking fluid or ORC fluid, that the wellhead fluid may not reachtemperatures sufficient to cause a vaporous phase change of the workingfluid or ORC fluid. As such, at block 718, the master controller mayclose the open wellhead fluid valves and, at block 720, close the heatexchanger valves 428.

FIG. 7B is another flow diagram of geothermal power generation in which,when a working fluid or ORC fluid is at or above a vaporous phase changetemperature threshold, heat exchanger valves may remain open to allowwellhead fluid to flow therethrough, thereby facilitating heating of theworking fluid or ORC fluid for use in an ORC unit, according to one ormore embodiment of the disclosure. The method is detailed with referenceto the master controller 402 and system 400 of FIGS. 4A and 4B. Unlessotherwise specified, the actions of method 701 may be completed withinthe master controller 402. Specifically, method 701 may be included inone or more programs, protocols, or instructions loaded into the memoryof the master controller 402 and executed on the processor or one ormore processors of the master controller 402. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

Blocks for FIG. 7B may perform the same functions as described forblocks of FIG. 7A. As such, those blocks include the same numbers, suchas block 702 through block 722. In addition to those operations, atblock 724 the master controller 402 may check whether the heat exchangervales may be open. If they are not the master controller 402 may openthe heat exchanger valves and close, at least partially, the wellheadfluid valves. If the heat exchanger valves are open, the mastercontroller 402 may not change or adjust any of the valves openpercentage, but rather continue to or start pumping the working fluid orORC unit through the ORC unit.

In addition, after the master controller 402 closes the heat exchangervalves at block 720, the master controller 402 may determine, at block726, the wellhead fluid temperature at the heat exchanger. At block 728,the master controller may determine whether the wellhead fluid is at avaporous phase change temperature of the working fluid or ORC fluid. Ifthe wellhead fluid temperature is less than such a value, the mastercontroller 402 may wait and measure the temperature again after a periodof time. If the wellhead fluid temperature is greater than or equal tosuch a value, the master controller 402 may perform the operations ofmethod 701 starting at block 724 again.

FIG. 8 is a flow diagram of geothermal power generation in which aworking fluid flow is determined based on a preselected electrical poweroutput threshold, according to one or more embodiment of the disclosure.The method is detailed with reference to the master controller 402 andsystem 400 of FIGS. 4A and 4B. Unless otherwise specified, the actionsof method 800 may be completed within the master controller 402.Specifically, method 800 may be included in one or more programs,protocols, or instructions loaded into the memory of the mastercontroller 402 and executed on the processor or one or more processorsof the master controller 402. The order in which the operations aredescribed is not intended to be construed as a limitation, and anynumber of the described blocks may be combined in any order and/or inparallel to implement the methods.

At block 802, each of one or more heat exchangers may be connected toone or more wellhead fluid lines. Each of the one or more wellhead fluidlines may correspond to a wellhead. At block 804, an ORC unit may beconnected to the one or more heat exchangers. In another example, thesystem 400 may include one or more ORC units and each of the one or moreORC units may connect to one or more heat exchangers or two or more heatexchangers.

At block 806, heat exchanger valves positioned between the one or moreheat exchangers and the one or more wellhead fluid lines may be opened.Once opened, the heat exchanger valves may allow for continuousdiversion of the flow of wellhead fluid through the heat exchanger. Theflow of wellhead fluid through the heat exchanger may facilitatetransfer of heat from the flow of wellhead fluid to a flow of workingfluid or intermediate working fluid.

At block 808, ORC unit valves may be opened. The ORC unit valves mayinitially be fully opened or partially opened. The ORC unit valves, whenopen, may allow for working fluid from each of the heat exchangers toflow into the ORC unit. Each working fluid flow may be combined and maypass through the ORC unit.

At block 810, the master controller 402 may determine one or moreoperating conditions of the ORC unit and/or the system 400. The one ormore operating conditions may include the flow rate and/or pressure ofworking fluid flowing through each of the one or more heat exchangers,the flow rate and/or pressure of wellhead fluid flowing through each ofthe one or more heat exchangers or at any other point downstream of thewellhead, the temperature of the working fluid in each of the one ormore heat exchangers, the temperature of wellhead fluid at each of theone or more heat exchangers, the temperature of the combined workingfluid flow at the ORC unit, the electrical power output from the ORCunit, and/or the open position of each of the valves included in thesystem 400.

At block 812, based on the determined operating conditions, the mastercontroller 402 may determine an optimal or efficient working fluid flowof the ORC unit. The optimal or efficient working fluid flow may dependon the temperature of the combined working fluid flowing to the ORCunit. The other operating conditions, described above, may be utilizedto determine the optimal or efficient working fluid flow. The optimal orefficient working fluid flow may comprise the combined flow of workingfluid flowing into the ORC unit to thereby produce a maximum amount ofelectrical power possible or to enable the ORC unit to meet apreselected electrical power output threshold. The optimal or efficientworking fluid flow may be at a temperature sufficient to produce such anamount of electrical power (e.g., a temperature greater than or equal tothe boiling point of the working fluid within the ORC unit). The optimalor efficient working fluid flow may be indicated by the mastercontroller 402 as one or more open positions for each of the ORC unitvalves and/or heat exchanger valves.

At block 814, the master controller 402 may, based on a determinedoptimal or efficient working fluid flow, determine whether to adjust theone or more ORC unit valves. Other valves within the system 400 may beadjusted based on the optimal or efficient working fluid flow, such asone or more heat exchanger valves and/or one or more wellhead fluidvalves. If it is determined that the ORC unit valves or any other valvesare to be adjusted, the master controller 402, at block 816, maytransmit a signal to the valve to be adjusted indicating a new openposition or closed position for the valve to adjust to. After the signalis transmitted, the valve may automatically adjust to the positionindicated. If the valve is not to be adjusted or after the valves havebeen adjusted, the master controller 402 may determine operatingconditions again. In an example, the master controller 402 may wait fora period of time, allowing the system to adjust to the new temperaturesand flow rates or to reach equilibrium, prior to determining theoperating conditions.

FIG. 9A, FIG. 9B, FIG. 9C, FIG. 9D, and FIG. 9E are block diagramsillustrating novel implementations of one or more geothermal powergeneration enabled wells to provide electrical power to one or more ofin-field equipment, equipment at one of the other wells, energy storagedevices, and the grid power structure, according to one or moreembodiment of the disclosure. As illustrated in FIG. 9A, various wells902A, 902B, up to 902N may be positioned in proximity to one another.For example, one well (e.g., well A 902A may be located at a distance ofover about 1 mile, about 5 miles, about 10 miles, about 25 miles, ormore to another well (e.g., well B 902B or well N 902N). Each well 902A,902B, 902N may include various in-field equipment 910A, 910B, 910N. Eachwell 902A, 902B, 902N may include one or more wellheads 904A, 904B,904N. Each wellhead 904A, 904B, 904N may connect to a high-pressure heatexchanger 906A, 906B, 906N and the high-pressure heat exchanger 906A,906B, 906N may connect to ORC equipment 908A, 908B, 908N. The ORCequipment 908A, 908B, 908N may generate electrical power. The electricalpower may be provided to the in-field equipment 910A, 910B, 910N. Asurplus of electrical power may be provided to an energy storage device920A, 920B, 920N. The ORC equipment 908A, 908B, 908N may also transmitelectrical power energy to other wells, energy storage devices, or to agrid power structure 912.

As noted and as illustrated in FIG. 9B, the high-pressure heat exchangerN 906N may connect to one or more wellheads 904A, 904B, 904N. Forexample, a well N 902 may include 1, 2, 3, or more wellheads (e.g.,wellhead A 904A, wellhead B 904B, and/or up to wellhead N 904N). All ofthe wellheads 904A, 904B, 904N may connect to one high pressure heatexchanger N 906N. In another example, a well N 902N may include one ormore high-pressure heat exchangers, as illustrated in FIG. 9D and FIG.9E. In such examples, the wellheads 904A, 904B, 904N may connect to oneor more of the high-pressure heat exchangers.

As described and as illustrated in FIG. 9C, the well N 902N may includeone or more wellheads (e.g., wellhead A 904A, wellhead B 904B, and/or upto wellhead N 904N), one or more sets of ORC equipment (e.g., ORCequipment A 908A, ORC equipment B 908B, and/or up to ORC equipment N908N), and one or more sets of in-field equipment (e.g., in-fieldequipment A 910A, in-field equipment B 910B, and/or up to in-fieldequipment N 910N). As noted, a well N 902N may include one high-pressureheat exchanger, as illustrated in in FIG. 9D and FIG. 9E. The well 902may further include additional high-pressure heat exchangers 906.

As illustrated in FIGS. 9D and 9E, a well N 902N may include one or morewellheads (e.g., wellhead A 904A, wellhead B 904B, and/or up to wellheadN 904N). Each of the one or more wellheads 904A, 904B, 904N maycorrespond to a high-pressure heat exchanger (e.g., heat exchanger A906A, heat exchanger B 906B, and/or up to heat exchanger N 906N). Inother examples, two or more high-pressure heat exchangers may correspondto a particular wellhead, while in other examples, two or more wellheadsmay correspond to a high-pressure heat exchanger. Further, a well N 902Nmay include one ORC equipment A 908A or unit, as illustrated in FIG. 9D.A well N 902N may include two ORC equipment (e.g., ORC equipment A 908Aand ORC equipment B 908B) or units or, in some cases, more. In suchexamples, each ORC equipment 908A, 908B may connect to each of thehigh-pressure heat exchangers 906A, 906B, 906N. As wellhead fluid flowsfrom a wellhead 904A, 904B, 904N, the temperature and pressure may varybased on a number of factors (e.g., production, type of fluids, distancefrom the high-pressure heat exchanger, among other factors).

As such, a working fluid of a particular high-pressure heat exchanger906A, 906B, 906N may be heated to a degree sufficient, insufficient, ormore than sufficient to cause the working fluid of the ORC equipment908A, 908B to exhibit a vaporous phase change. Since the temperature ofthe wellhead fluid varies, a controller (e.g., controller 916A, 916B, upto 916N or master controller 918, as illustrated in FIG. 9F) maydetermine the temperature of working fluid at each high-pressure heatexchanger 906 and determine the most efficient and/or optimalcombination to be utilized for generating the most electrical power orfor generating an amount of electrical power to meet a preselectedelectrical power output threshold at the ORC equipment 908A, 908B. Theelectrical power output by the ORC equipment 908A, 908B may be measuredby, for example, an electrical power meter or other device suitable todetermine electrical power output. The controller may also determine thetemperature of the combination of working fluid or intermediate workingfluid entering the ORC equipment 908A, 908B, via, for example, one ormore temperature sensors positioned at or near an inlet of the ORCequipment 908A, 90B. The inlet may allow working fluid or intermediateworking fluid to flow into the ORC equipment 908A, 908B. The controllermay determine the most efficient and/or optimal combination or amount ofworking fluid or intermediate working fluid from the one or morehigh-pressure heat exchangers 906A, 906B, 906N based on a variety offactors noted above. For example, the most efficient and/or optimalcombination or amount may be based on wellhead fluid temperature fromeach of the one or more wellheads 904A, 904B, 904N, the working fluid orintermediate working fluid temperature at each of the high-pressure heatexchangers 906A, 906B, 906N, and/or electrical power output (e.g., ameasurement indicative of the electrical power generated) by the ORCequipment 908A, 908B. Other factors may include flow rate and pressureof each of the high-pressure heat exchangers 906A, 906B, 906N, currentopen positions high-pressure heat exchanger valves, and/or current openpositions of other valves included at the well N 902N.

For example, if high-pressure heat exchanger A 906A includes a workingfluid at a temperature slightly less than a temperature to causevaporous phase change, then valves providing working fluid orintermediate working fluid from the high-pressure heat exchanger A 906Ato the ORC equipment 908A, 908B may be closed. In another example, ifhigh-pressure heat exchanger B 906B is providing working fluid at atemperature well above a temperature to cause vaporous phase change,then valves providing working fluid or intermediate working fluid fromhigh-pressure heat exchanger B 906B to ORC equipment A 908A and/or toORC equipment B 908B may be adjusted to positions such that a greaterportion of the working fluid or intermediate working fluid istransported to ORC equipment A 908A and/or to ORC equipment B 908B.

In yet another example, all valves for allowing flow of working fluid orintermediate working fluid to the ORC equipment A 908A and/or ORCequipment B 908B may be, at least, in a partially open position. Thetemperature of the wellhead fluid and/or working fluid of each heatexchanger 906A, 906B, 906N may be determined or measured. Further, theelectrical power output of the ORC equipment A 908A and/or ORC equipmentB 908B may be determined. The positions of each valve for allowing flowof working fluid or intermediate working fluid to the ORC equipment A908A and/or ORC equipment B 908B may be adjusted to different partiallyopen positions, fully opened positions, or fully closed positions. Suchvalve adjustments may be based on maximization of the resultanttemperature and heat delivered to the ORC equipment A 908A and/or ORCequipment B 908B once the combined working fluid flows into the ORCequipment 908 A 908A and/or ORC equipment B 908B. The valve adjustmentsmay be based on, rather than or in addition to other factors, themaximization of the electrical power output from the ORC equipment A908A and/or ORC equipment B 908B. Valve adjustments may further be basedon wellhead fluid temperature and/or some combination of the factorsdescribed herein.

As noted and described above and as illustrated in FIG. 9F, a controller(e.g., controller A 916A, controller B 916B, and/or up to controller N916N) may be included at one or more of the wells 902A, 902B, 902N. Thecontroller 916A, 916B, 916N may control and monitor various aspects ofthe well 902A, 902B, 902N. The controller 916A, 916B, 916N of each well902A, 902B, 902N may connect to a master controller 918, the mastercontroller 918 may control the operations of the ORC equipment 908A,908B, 908N, as well as other equipment (e.g., valves and/or pumps) ateach of the wells 902A, 902B, 902N. As described above and illustratedin FIG. 9G, the master controller 918 may connect to one or morewellheads 904A, 904B, 904N. The ORC enabled wells 902A, 902B, 902N mayprovide power to one or more of in-field equipment at the ORC enabledwell 902A, 902B, 902N, to an energy storage device, and/or a gridstructure device (see 912).

According to another embodiment of the present disclosure shown in FIGS.10A-11 , a system 1000 for generation of power in an organic Rankinecycle (ORC) operation by utilization of heat generated by one or moreheat sources 1001 at or in the vicinity of a site of hydrocarbonproduction or other location, and supplied to one or more mobile heatgeneration units 1002 for heating a working fluid that is passed throughan ORC unit for driving a generator thereof, is provided according toprinciples of the present disclosure. The ORC unit can include an ORCunit such as shown at 106 in FIG. 1A and can be constructed and operablein a manner as disclosed in any of the prior embodiments discussed aboveand illustrated with regard to any of FIGS. 1A-9G to generate electricalpower.

The mobile heat generation unit 1002 shown in the system 1000 (FIG. 11 )of the present embodiment is configured to provide a substantiallyself-contained heat generation module, skid or package that is readilytransportable to hydrocarbon production sites such as drilling sites,pumping stations, well sites, and/or other remote locations, and isadapted to utilize what would otherwise be wasted heat coming fromvarious heat sources 1001 and the site. Such heat sources 1001 canprovide flows of a heated fluid such as high temperature and/or highpressure gases or liquids, and can include, but are not limited to, oneor more infield equipment components such as fracturing equipment, fieldcompressors, pump stations, artificial lift equipment, drilling rigs,data vans, gas coolers, pump jacks and various other pumps, engines,and/or other equipment, as well as heat from a wellhead fluid and otherheat sources.

In the present embodiment, the site (e.g. a well 100 or pumping stationas shown in FIGS. 1A-1B) can be provided with one or more mobile heatgeneration units 1002 (FIGS. 10A-11 ) that each will receive a heatedfluid flow from one or more heat sources. For example, in theillustrated embodiment, the heat source 1001 (FIG. 11 ) can comprise anengine powered by natural gas or other type of fuel and used to drive orpower equipment such as pumps or gas coolers, etc., at a hydrocarbonproduction site. The engine will generate a heated exhaust gas that issupplied as a heated fluid flow this is supplied along a first fluidpath indicated at 1003, to and through a heat exchanger 1005 of a mobileheat generation unit 1002. The mobile heat generation unit 1002 can beconnected to the engine by an exhaust conduit or duct 1004, thatchannels/directs the heated fluid flow of exhaust gas to the mobile heatgeneration unit.

An example embodiment of a mobile heat generation unit and featuresthereof is shown in FIGS. 10A-12G. As illustrated, each mobile heatgeneration unit will be formed/constructed as a module or skid that canbe produced as a pre-configured package having a series of operativecomponents, including one or more heat exchangers 1005.

The heat exchangers 1005 (FIGS. 10A-11 ) of the mobile heat generationunit will be adapted to transfer heat from the incoming heated fluidflow 1003 (e.g. the exhaust gases from an engine supplied along theexhaust conduct or duct 1004) supplied along the first fluid path to aworking fluid that is supplied along a second fluid path as indicated at1007 in a substantially closed recirculation loop wherein the workingfluid is pumped through the heat exchangers and one or more ORC units106 connected thereto. As noted, the heated fluid flows supplied fromthe one or more heat sources to the heat exchangers along the firstfluid path 1003 are not limited to exhaust gases from an engine and caninclude various high pressure and/or high temperature liquid or gasflows supplied along various types of piping or suppliers. For example,a high pressure wellhead fluid can be supplied to and passed through theheat exchangers 1005 (FIGS. 10A-10H) of one or more mobile heatgeneration units 1002 for transfer of heat from such a harsh pressurefluid to the working fluid.

The heat exchangers 1005 installed in the mobile heat generation unitwill include selected type and/or capacity heat exchangers that can beselected based upon an estimated mass flow volume or range of mass flowvolumes of the heated fluid to be supplied thereto. For example, and notlimitation, each mobile heat generation unit can be constructed/producedas a substantially standardized or “off-the shelf” heat generationpackage with between 50%-80% and/or up to 100% selected operativecomponents, such as one or more pumps, piping, etc., and one or moreselected heat exchangers that can be pre-installed therein prior toshipment. As used herein, the operative components of the mobile heatgeneration unit can include the one or more heat exchangers, pumps,piping, valves, sensors, an expansion tank, air separator, and/or otherequipment as will be understood by those skilled in the art.

Thus, rather than requiring a custom designed geothermal powergeneration system wherein components such as individual heat exchangers,pumps etc. are separately transported and assembled at a hydrocarbonproduction site, including assembling and connecting individual heatexchangers to necessary piping and integrating control thereof in thefield, the mobile heat generation unit 1002 provides a compact,transportable and reusable heat generation module or package with one ormore heat exchangers of a selected type and/or capacity pre-installedwith at least one pump and piping for pumping or recirculating a flow ofworking fluid therethrough. The entire package further can be easilytransported to a hydrocarbon production site or other location and canbe quickly and easily connected one or more ORC units and to one or moreheat sources, such as to exhaust conduits or ducts 1004 for one or moreengines (FIG. 11 ).

As shown in FIGS. 10A-10H, each mobile heat generation unit 1002includes a frame 1010 having an upper or top portion 1011, a lower orbottom portion 1012, sides 1013, and proximal and distal ends 1014 and1016. As indicated, the frame generally can be constructed as having asubstantially rectangular or cube shape or configuration, although otherconfigurations also can be provided, including a series of peripheralframe beams or supports 1017 defining a chamber 1018 within the frame,and within which the operative components of the mobile heat generationunit, including the one or more heat exchangers 1005, are arranged andmounted. The frame 1010 also can include a series additional supportbeams 1019 arranged at spaced locations along the upper and lowerportions 1011 and 1012 of the frame and along the sides 1013 of theframe; and at other locations as needed. One or more of the additionalsupport beams 1019 further can be removably mounted to the peripheralframe beams 1017, such as by fasteners or other removable connections,to enable removal and replacement or repositioning of such additionalsupport beams as needed. As further illustrated in FIGS. 10D-10F and10H, planks 1021 can be arranged along the lower or bottom portion 1012of the frame 1011, defining a floor 1022 for the mobile heat generationunit 1002. The floor 1022 can include a series of spaced planks 1021,with gaps defined therebetween, or can comprise a substantially solidfloor structure to deter animals, etc. from entering into the mobileheat generation unit.

In embodiments, the transportable package, module or skid defined by themobile heat generation unit 1002 can be configured with a footprint thatis substantially equivalent to that of an ISO shipping container, so asto be adapted for intermodal transportation along highways. For example,the mobile heat generation unit can have a substantially square orrectangular footprint with lengths ranging from about 15 feet to about40 feet, widths of between about 5 feet to about 14 feet, and heights ofbetween about 6 feet to about 10 feet to accommodate differentarrangements and/or numbers of heat exchangers as needed for aparticular application, while still enable transport along an interstatehighway. Other dimensions also can be provided. In addition, thesubstantially skeletonized frame 1010 illustrated in FIGS. 10A-10Hfurther can help reduce weight of the mobile heat generation unit forease of transport, loading, and unloading of the mobile heat generationunit at a hydrocarbon production site or other location.

By way of example only, in embodiments, mobile heat generation units canbe constructed with 1-2 heat exchangers in a package, skid or modulehaving a length of about 20 feet, a width of approximately 8-10 feet,and a height of at least 8 feet, and can be transported and delivered toa site by a conventional semi-tractor trailer. In other embodiments, themobile heat generation units can be constructed with a length upwards ofapproximately 40 feet, a width of approximately 8-10 feet, and a heightof at least approximately 8 feet and can incorporate more (e.g. 3-6)heat exchangers. Other varying sizes and configurations of theprepackaged mobile heat generation units according the principals of thepresent disclosure, also can be provided. The construction of the mobileheat generation unit as a substantially pre-assembled/pre-configuredmodule or package enables production of substantially uniform orgenerally standardized heat generation units that produced off-site withone or more selected heat exchangers, including high pressure heatexchangers configured to receive heated fluid flows of a selected type,e.g. high temperature high pressure liquid or gas fluid flows, and/ordifferent capacity heat exchangers, packaged therein for ease andefficiency of shipment and installation at a site.

As further illustrated in FIG. 10H, a series of cover panels 1026 can beinstalled along the upper or top portion 1011, the sides 1013, and theproximal and distal ends 1014 and 1016 of the frame 1010. The coverpanels can form a protective skin or outer covering to enclose thechamber 1018 and operative components of the mobile heat generation unitcontained therein. While the operative components of the mobile heatgeneration unit generally will be weather resistant rated (including theheat exchanger(s) 1005), the cover panels 1026 can help protect suchcomponents from extreme weather and during transport and deter accessthereto by unauthorized personnel, animals, etc. during transport andafter installation.

The cover panels generally can be formed from a rigid, durable material,such as a corrugated steel or other, similar metal material selected fordurability without substantially increasing the weight of the overallpackage of the mobile heat generation unit, while enclosing andprotecting the operative components of the mobile heat generation unit.Other rigid, durable materials also can be used for the cover panels. Atleast some of the cover panels 1026 further can be releasibly attachedor mounted to the peripheral frame beams 1017, such as by a limitednumber (e.g., 5-10) of bolts, screws or other fasteners or othermechanical connections. As a result, at least a portion of the coverpanels can be selectively removable as needed for enabling access to thechamber defined within the frame, and to the operative components of themobile heat generation unit housed therein.

For example, if there is a need or a desire to change one or more of theheat exchangers 1005 of the mobile heat generation unit 1002, such as tosubstitute an exhaust heat exchanger for a different capacity or type ofheat exchanger (e.g. a heat exchanger designed to extract heat fromcompressed gas or from a heated fluid or a high pressure fluid such as awellhead fluid) one or more of the cover panels 1026 along the top orupper portion 1011 of the frame 1010 can be removed, as can one or moreof the additional beams or supports 1019 as needed, to enable theremoval and/or change-out of one or both of the heat exchangers throughthe top of the frame.

Such a change-out or substitution of the heat exchangers can beaccomplished without requiring a substantial reconstruction of theentire mobile heat generation unit, and can be accomplished in the fielde.g. at the hydrocarbon production site or other location, or can bedone at a manufacturing or storage facility. The mobile heat generationunits of the present disclosure thus can be reconfigured as neededwithout affecting their ability to be produced and transported to a siteas pre-packaged, substantially ready-to-use modular mobile heatgeneration units that also can be relocated from one site to anotherwithout having to substantially deconstruct and the reconstruct theentire heat exchange assembly at each site. In addition, as indicated inFIGS. 12B and 12C, selected ones of the cover panels also can beprovided with pre-defined ports or openings to receive and connect theexhaust conducts or ducts or piping supplying the heated fluid to theone or more heat exchangers.

As shown in FIGS. 10A-10H, in some embodiments the heat exchangers 1005of the mobile heat generation unit 1002 generally will be mounted onraised platforms 1030 within the chamber 1018 of the frame so as tolocate the heat exchangers at raised or elevated positions. This canfacilitate access to and removal of the heat exchangers from the top ofthe frame of the mobile heat generation unit, and further can facilitateaccess thereto from within the chamber for servicing. In addition, inthe illustrated embodiment showing two heat exchangers 1005 mountedwithin the chamber, one of the heat exchangers is illustrated as beingarranged adjacent the distal end 1016 of the frame, while the other heatexchanger is located closer to the proximal end 1014 of the frame.However, other configurations also can be provided. The chamber 1018defined by the frame additionally can be divided into sections orquadrants, including at least a first section 1031A in which at leastsome of the operative components of the mobile heat generation unit,including the heat exchangers, will be located, and a second section1031B at the proximal end 1014 of the frame.

A control cabinet or area 1032 can be provided within the second section1031B, as indicated in FIGS. 10B, 10C and 10G, with the second sectionfurther including an exterior door for closing access thereto fromoutside the mobile heat generation unit. An additional door or accesspanel can be provided on an interior wall of the control area 1032between the first and second sections 1031A/1031B of the chamber, and/oralong one or more of the sides and/or the distal end of the frame toenable access to the operative components housed within the firstsection 1031A of the chamber. The control area 1032 also generally canbe insulated or heat traced so as to protect the unit controls housedtherein from heat generated by heat exchangers.

The control area will house a controller 1035 for the mobile heatgeneration unit 1002. The controller 1035 can include at least oneprocessor and a control panel 1037 that can include a user interface(e.g., display/touch screen, keyboard, etc.), and will be programmedand/or configured to communicate with, monitor and control operation ofthe various operative components of the mobile heat generation unit. Forexample, as indicated in FIG. 11 , the controller 1035 will monitor oneor more sensors 1038 arranged at various locations within the mobileheat generation unit to provide readings of temperature as pressure ofthe incoming heated fluid flow 1003 and the working fluid flow 1007, andin response, control operation of the heat exchangers and other ones ofthe operative components.

As noted, in the illustrated example embodiment, a pair of exhaust gasheat exchangers 1005 are shown, and can be selected and sized toaccommodate an estimated or mass flow. As indicated FIG. 11 , each ofthe heat exchangers 1005 generally will be connected to an exhaustconduit or duct 1004 that supplies the heated exhaust gas flow indicatedalong the first fluid flow path at arrows 1003, and a vent or outletpipe 1042. For example, cover panels 1026 arranged on opposite the sidesof the mobile heat generation unit can be removed or can be providedwith ports or openings through which the exhaust conduits or ductsextending from the one or more heat sources and the vent or outlet pipesconnected to the heat exchangers are received.

As further illustrated in FIG. 11 , each exhaust conduit or duct 1004can include a damper valve 1043 that can be selectively opened andclosed by an actuator 1044, such as a motor or hydraulic actuator, undercontrol of the controller 1035 for the mobile heat generation unit. Apressure sensor 1046 can be provided at or near the junction orconnecting pipe 1047 between each exhaust conduit and its heatassociated exchanger to measure an incoming flow rate or pressure of theexhaust gas being supplied along each exhaust conduit or duct 1004 tothe heat exchangers. Based on a measured pressure or fluid flow rate,the damper valves 1043 can be opened or closed as needed to control thepressure and/or mass flow volume of the exhaust gasses feeding into theheat exchangers.

In addition, it will be understood by those skilled in the art thatwhile a pair of heat exchangers are shown in a present embodiment, inother embodiments, a single heat exchanger could be used, or more thantwo heat exchangers also can be used, e.g. the mobile heat generationunit can be packaged with 3, 4, 5 or 6 (or more) heat exchangers.

Each mobile heat generation unit further will include a fluidrecirculation system 1050, along which the second fluid path 1007 isdefined an extends. The fluid recirculation system will including fluidintake conduit 1051 configured to couple to a return line 1052 that isin fluid communication with the at least one ORC 106 unit for receivingthe working fluid therefrom; a fluid outlet conduit 1054 configured tocouple to a heated working fluid supply line that is in fluidcommunication with the at least one ORC unit for supplying the heatedworking fluid to the at least one ORC unit, a pump 1057, and an array ofpiping 1058 including a first section of piping at 1059A, connecting thepump to the heat exchangers and a second section of piping 1059Bconnecting the heat exchangers to the fluid outlet conduit. As indicatedin FIGS. 10A and 10D-10G, the pipes of the array of piping can bearranged at an elevated position, e.g. raised above the floor of thechamber to facilitate access thereto and to further help protect workersfrom contact therewith and further will be heat traced or insulated toprotect workers that may come into contact with such pipes.

The mobile heat generation unit will be connected to the at least oneORC unit in a substantially closed fluid recirculation loop arrangementwhereby the heated working fluid, such as a deionized water mixture orother working fluid such as pentafluoropropane, carbon dioxide, ammoniaand water mixture, tetrafluoroethane, isobutene, propane, pentane,perfluorocarbons, and other hydrocarbons mixtures as disclosed above,will be supplied to and returned from the at least one ORC unit. As theworking fluid is moved along the second fluid path through the closedfluid recirculation loop defined between the ORC unit and the mobileheat generation unit, the working fluid is heated by transfer of heatfrom the heated flow passing through the heat exchangers along the firstfluid path so that the working fluid will be output and supplied to theORC unit at a temperature approximately at or above its boiling point,whereupon the liquid working fluid will change from a liquid to vaporphase.

As the heated (e.g. vaporous phase) working fluid is circulated throughthe ORC unit, it can pass through a gas expander that can rotate so asto drive a generator 1061 for generation of electrical power, such asdiscussed above with respect to embodiments of the ORC unit as shown inFIGS. 2A-2H. The electrical power generated by the ORC unit can bediverted to provide power to drive one or more of the operativecomponents of the hydrocarbon production site, including being suppliedto the mobile heat generation unit via a power connection line; or canbe provided to the electrical grid or an energy storage device asfurther discussed with respect to any of the above disclosedembodiments. Thereafter, the working fluid can pass through a condenserand/or heat sink that can condenses the vaporous working fluid to asubstantially cooled, liquid state that is provided back to the mobileheat generation unit via the fluid inlet conduit 1051.

As discussed with respect to the above embodiments, the ORC unit furthergenerally will include a controller that can monitor the incoming andoutgoing working fluid flows, e.g. receiving inputs from a series ofsensors 1062 (FIG. 11 ) monitoring pressure, temperature, etc. of theworking fluid and can control the flow thereof to prevent the heatedworking fluid flow from looping back on itself. The controller of theORC unit further can be connected to the controller of the mobile heatgeneration unit by a data connection, such as by a common data and powerconnection or coupling through which power can be supplied to the mobileheat generation unit and data transferred between the mobile heatgeneration unit from the ORC unit. As also noted, each ORC unitconnected to the mobile heat generation unit can be configured and canbe operated in accordance with any of the above discussed embodiments ofthe present disclosure.

As illustrated in FIGS. 10D-10E and, the fluid intake conduit 1051 caninclude a coupling 1068 at a first end thereof, which coupling generallycan be arranged along the top or upper portion 1012 of the frame 1010,at the proximal end 1014 thereof. The fluid intake conduit generallywill initially extend into the chamber along the upper portion thereof,extending over the control area/first section 1031B, and as it entersthe second section 1031B of the chamber, can be directed downwardly toconnect to the pump 1057 as shown in FIG. 10G, for supplying the workingfluid received from the ORC unit at a first temperature wherein theworking fluid is in a substantially cooled, liquid phase. The pump 1057generally will include a variable speed pump that will be linked to andcontrolled by the controller 1035 to control a rate at which of workingfluid is fed through the recirculation system 1050. The pump 1057 willreceive and pump the working fluid along a flow path 1066 defined by thearray of piping 1058 arranged within the second section 1031B of thechamber to feed the working fluid through the heat exchangers.

In the embodiment shown in FIGS. 10D-10G, the first section of piping1059A extends from the pump 1057 to a splitter or manifold 1067 havingcontrol valve 1068, and which forms a T-junction between first sectionof piping 1059A and each heat exchanger 1005. The working fluid can bedivided between and supplied to each heat exchanger wherein the workingfluid passing along the second fluid path 1007 through each heatexchanger will be heated via heat transfer from the heated fluid flowspassing along the first fluid path through each heat exchanger. Thecontroller 1035 of the mobile heat generation unit can monitor the flowof heated fluid coming into each heat exchanger (e.g. the mass flow ofincoming exhaust gas), and can accordingly adjust the flow of workingfluid supplied to each heat exchanger through manipulation of thecontrol valve 1068 to ensure substantially optimum operation of the heatexchangers, and to provide a maximum heated working fluid outflow forsupply to the ORC unit.

As indicated, the control valve 1068 of the splitter 1057 can be openedand closed to selectively divert more or less volumes of the workingfluid into each of the heat exchangers through an inlet port 1070adjacent a first or upstream portion thereof. As the working fluidpasses through the heat exchangers, heat from the incoming heated fluidflow (e.g. heated exhaust gases passing along the first fluid path) istransferred to the working fluid. The working fluid is heated within theheat exchangers to a second temperature that is greater than the firsttemperature, and which generally will be at or above a boiling point ofthe working fluid whereupon the working fluid changes to its a vaporphase as it is output from the heat exchangers through a downstream port1071 and to the second section of piping 1059B of the array of piping.The heated working fluid thereafter can be fed through a manifold 1072that can include a control valve 1073 operable to regulate the flow ofthe heated working fluid from one or both of the heat exchangers forfeeding to the ORC unit. The manifold generally will be linked to thefluid outlet conduit 1052, which will extend along a portion of thechamber and will be directed upwardly to the top or upper portion of thechamber, terminating at an outlet coupling or connector 1074 adjacent tothe top portion of the frame at the approximately and thereof.

As further illustrated in FIGS. 10C-10D and 11 , the mobile heatgeneration unit 1002 can include an expander 1076 having an expansiontank 1077 (FIG. 11 ), with an inlet valve 1078 that can be controlled(e.g. opened and closed) by the controller 1035 of the mobile heatgeneration unit. One or more pressure sensors 1079 can be provided alongthe array of piping so as to detect an increase in pressure of theincoming working fluid that would raise its temperature substantiallytoward its vapor point, and in response, the controller can open theinlet valve of the expansion tank, to enable excess working fluid to bedrawn off so as to reduce or control the pressure of the flow of workingfluid as needed.

In addition, an air separator can be provided along array of piping, forexample along the second section of piping. The air separator generallywill be configured and can be operable to filter out particulates fromthe working fluid, and/or to drain or bleed off excess air from therecirculating system 1050, such as on startup of the mobile heatgeneration unit.

As further illustrated in FIG. 11 , the mobile heat generation unit 1002can include, or can be connected to, a weather station 1080 having anarray of weather sensors configured to monitor and report environmentalconditions at or around a hydrocarbon production site location at whichthe mobile heat generation unit is installed. For example, sensorsmeasuring ambient temperature, barometric pressure and otherenvironmental conditions can be provided, either as part of a standaloneweather station connected to the mobile heat generation unit, or as anincluded array of sensors within the transportable package defined bymobile heat generation unit. The readings of temperature, pressure, etc.relating to the ambient weather conditions will be supplied to thecontroller 1035 for the mobile heat generation unit, which accordinglycan adjust the intake of the heated fluid flow from the heat source(s)along the first fluid path into and through the one or more heatexchangers and/or the circulation of the working fluid along the secondfluid path, based on such measured ambient weather conditions. Forexample, the controller can open or close one or more of the damperand/or control valves for regulating or diverting the incoming heatedfluid flow, and/or the flow of the working fluid between the heatexchangers as needed to ensure a substantially consistent flow of thehighest temperature working fluid to be produced and supplied to the ORCunit.

The mobile heat generation unit additionally will include UPC batterybackup or other alternative power source that can automatically beengaged. In the event that exhaust streams or other incoming streams orflows of the heated fluid fail, and/or the mobile heat generation unitloses a connection to a direct power source (e.g. an ORC unit providingto a direct power source to the mobile heat generation unit is shut downor otherwise the power connection is lost), the battery backup systemcan be automatically turned on to provide power to the controller 1035and at least some of the operative components of the mobile heatgeneration unit.

In embodiments, the mobile heat generation unit further can include oneor more drain or dump valves arranged along the array of piping. Whilethe array of piping generally will be insulated to both prevent orreduce the incidence of personnel being burned or otherwise injured whenthey come into contact with such piping, and protect the piping fromsubfreezing temperatures, in the event of a system power loss and/orloss of the flows of heated fluid into the mobile heat generation unit,and subfreezing temperatures being detected by the controller, thecontroller can engage and operate one or more of the drain or dumpvalves to enable drainage of deionized water out of the array of pipingin order to prevent freezing of the deionized water within the piping,which can cause splitting or otherwise damage to the operativecomponents of the mobile heat generation unit.

As noted above, the mobile heat generation unit 1002 according to thepresent embodiment, can be used in place of one or more high pressureheat exchangers as disclosed with respect to any of the embodimentsdisclosed and/or taught by the present disclosure. The mobile heatgeneration unit is designed to provide a transportable, substantiallyself-contained and ready to operate package or module that can beproduced with pre-installed operative components, such as pump andrecirculation system, as well as one or more heat exchangers of aselected type and/or capacity, within a substantially standardizedfootprint. The pre-packaged mobile heat generation unit can be easilytransported, such as by a semi-tractor trailer, and can be located andinstalled at a site being easily and efficiently connected or coupled toa heat source and to an ORC unit at the site, without having toseparately ship components such as heat exchangers and assemble suchcomponents at the site. Additional mobile heat generation units furthercan be transported to a job site, and can be connected in series to apreviously installed mobile heat generation unit and to additional heatsources, as well as one or more ORC units as needed. The mobile heatgeneration units further can be removed from a site and readilytransferred to another site for use.

It will be understood by those skilled in the art that the mobile heatgeneration unit according to the principles of the present disclosurefurther can be utilized with any of the systems and/or methods forgenerating geothermal power in an ORC operation presented in thisdisclosure, including systems and methods for generating power in an ORCoperation during hydrocarbon production based on working fluidtemperature and/or pressure provided in any of the previously discussedembodiments of the present disclosure.

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/657,721, filed Apr. 1, 2022, titled “Modular Mobile HeatGeneration Unit for Generation of Geothermal Power in Organic RankineCycle Operations,” which claims priority to and the benefit of U.S.Provisional Application No. 63/269,862, filed Mar. 24, 2022, titled“Systems and Methods for Generation of Electrical Power at a DrillingRig,” and U.S. Provisional Application No. 63/269,572, filed Mar. 18,2022, titled “Systems and Methods for Generation of Electrical Power ata Drilling Rig,” U.S. Provisional Application No. 63/261,601, filed Sep.24, 2021, titled “Systems and Methods Utilizing Gas Temperature as aPower Source,” and U.S. Provisional Application No. 63/200,908, filedApr. 2, 2021, titled “Systems and Methods for Generating GeothermalPower During Hydrocarbon Production,” the disclosures of all of whichare incorporated herein by reference in their entireties. U.S.Non-Provisional application Ser. No. 17/657,721 is also acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/657,009, filed Mar. 29, 2022, titled “Systems and Methods forGeneration of Electrical Power at a Drilling Rig,” which claims priorityto and the benefit of U.S. Provisional Application No. 63/269,862, filedMar. 24, 2022, titled “Systems and Methods for Generation of ElectricalPower at a Drilling Rig,” and U.S. Provisional Application No.63/269,572, filed Mar. 18, 2022, titled “Systems and Methods forGeneration of Electrical Power at a Drilling Rig,” U.S. ProvisionalApplication No. 63/261,601, filed Sep. 24, 2021, titled “Systems andMethods Utilizing Gas Temperature as a Power Source,” and U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 is also a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/305,297, filed Jul. 2, 2021, titled “Systems forGenerating Geothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production Based on Working Fluid Temperature,” which claimspriority to and the benefit of U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009is a continuation-in-part of U.S. Non-Provisional application Ser. No.17/578,520, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” now U.S. Pat. No. 11,326,550, issuedMay 10, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/261,601, filed Sep. 24, 2021, titled“Systems and Methods Utilizing Gas Temperature as a Power Source,” andU.S. Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 also further is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/578,528, filed Jan. 19, 2022,titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” which claims priority to and the benefit of U.S. ProvisionalApplication No. 63/261,601, filed Sep. 24, 2021, titled “Systems andMethods Utilizing Gas Temperature as a Power Source,” and U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 still further is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/578,542, filed Jan. 19, 2022,titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” now U.S. Pat. No. 11,359,576, issued Jun. 14, 2022, whichclaims priority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009additionally is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,550, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009is also a continuation-in-part of U.S. Non-Provisional application Ser.No. 17/650,811, filed Feb. 11, 2022, titled “Systems for GeneratingGeothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production Based on Wellhead Fluid Temperature,” which is acontinuation of U.S. Non-Provisional application Ser. No. 17/305,298,filed Jul. 2, 2021, titled “Controller for Controlling Generation ofGeothermal Power in an Organic Rankine Cycle Operation DuringHydrocarbon Production,” now U.S. Pat. No. 11,280,322, issued Mar. 22,2022, which claims priority to and the benefit of U.S. ProvisionalApplication No. 63/200,908, filed Apr. 2, 2021, titled “Systems andMethods for Generating Geothermal Power During Hydrocarbon Production,”the disclosures of all of which are incorporated herein by reference intheir entireties. U.S. Non-Provisional application Ser. No. 17/657,009further still is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/670,827, filed Feb. 14, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” now U.S. Pat. No. 11,421,663, issued Aug. 23, 2022,which is a continuation-in-part of U.S. Non-Provisional application Ser.No. 17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. U.S. Non-Provisional application Ser. No.17/657,009 yet further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/682,126, filed Feb. 28, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” now U.S. Pat. No. 11,359,612, issued Jun. 14, 2022,which is a continuation of U.S. Non-Provisional application Ser. No.17/494,936, filed Oct. 6, 2021, titled “Systems and Methods forGeneration of Electrical Power in an Organic Rankine Cycle Operation,”now U.S. Pat. No. 11,293,414, issued Apr. 5, 2022, which is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties.

In the drawings and specification, several embodiments of systems andmethods to provide geothermal power in the vicinity of a wellhead duringhydrocarbon production have been disclosed, and although specific termsare employed, the terms are used in a descriptive sense only and not forpurposes of limitation. Embodiments of systems and methods have beendescribed in considerable detail with specific reference to theillustrated embodiments. However, it will be apparent that variousmodifications and changes can be made within the spirit and scope of theembodiments of systems and methods as described in the foregoingspecification, and such modifications and changes are to be consideredequivalents and part of this disclosure.

What is claimed is:
 1. A system to generate power in an organic Rankinecycle (ORC) operation, the system comprising: at least one ORC unitconfigured to generate electrical power; and at least one mobile heatgeneration unit in fluid communication with the at least one ORC unitand configured to operate with one or more heat sources supplying a highpressure or high temperature fluid to the at least one mobile heatgeneration unit; wherein the mobile heat generation unit is configuredas a transportable module and comprises: a frame having an upperportion, a lower portion and a plurality of side portions so ascollectively to define a chamber therein; at least one heat exchangermounted within the chamber and configured to connect to at least one ofthe one or more heat sources, the at least one heat exchanger mountedwithin the chamber at an elevated position adjacent the upper portion ofthe frame to facilitate access to the at least one heat exchanger fromwithin the chamber and through the upper portion of the frame; a fluidrecirculation system at least partially located within the chamber andcomprising: a fluid intake conduit coupled to a return line in fluidcommunication with the at least one ORC unit to receive a working fluidat a first temperature from the at least one ORC unit, a fluid outletconduit configured to couple to a heated fluid supply line in fluidcommunication with the at least one ORC unit to supply the working fluidthereto, wherein the working fluid is output to the fluid supply linefor supply to the ORC unit at a second temperature that is higher thanthe first temperature when passing therethrough, a pump connected to thefluid intake conduit and configured to pump the working fluid receivedthrough the fluid intake conduit through the fluid recirculation system,a piping array, including a first section of piping extending betweenthe pump and the at least one heat exchanger to supply the working fluidto the at least one heat exchanger, and a second section of pipingextending between the at least one heat exchanger and the fluid outletconduit, so that as the working fluid passes along the piping array andthrough the at least one heat exchanger, heat from the high pressure orhigh temperature fluid supplied to the at least one heat exchanger fromthe one or more heat sources transfers to the working fluid so as toheat the working fluid to the second temperature that is greater thanthe first temperature, and a controller positioned within the frame, thecontroller having programming configured to monitor temperature,pressure, or a combination thereof of the working fluid passing along afluid recirculation loop defined between the mobile heat generation unitand the at least one ORC unit and to regulate flow of the working fluidthrough the at least one heat exchanger for transfer of heat from theflow of the high pressure or high temperature fluid to the working fluidfor supply to the at least one ORC unit.
 2. The system of claim 1,wherein the at least one mobile heat generation unit includes at leasttwo heat exchangers configured to extract heat from a compressed gas, aheated exhaust gas, a heated liquid, or combination thereof.
 3. Thesystem of claim 1, wherein the at least one mobile heat generation unitfurther comprises an air separator along the second section of piping,the air separator configured to remove particulates from the workingfluid.
 4. The system of claim 1, wherein the at least one mobile heatgeneration unit has a length of between approximately fifteen feet toapproximately twenty feet.
 5. The system of claim 1, wherein the atleast one mobile heat generation unit further comprises a plurality ofcover panels positioned along the upper and lower portions and the sideportions of the frame, so as to substantially enclose the chamber, andwherein at least one or more of the cover panels are configured to beremovable from the frame to enable access to the chamber.
 6. The systemof claim 5, wherein one or more of the cover panels along the upperportion are removable to enable removal and replacement of the at leastone heat exchanger.
 7. The system of claim 1, wherein the at least onemobile heat generation unit further comprises an expansion tank locatedin fluid communication with the first section of piping, and wherein thecontroller includes programming configured to regulate flow of theworking fluid into the expansion tank so as to reduce the pressure ofthe working fluid.
 8. The system of claim 1, wherein the chamber of theframe comprises a plurality of quadrants including at least a firstquadrant defining a control cabinet housing the controller and a secondquadrant defining a working area in which the at least one heatexchanger and the fluid recirculation system are located.
 9. The systemof claim 1, further comprising a power and data connection extendingbetween the at least one ORC unit and the at least one mobile heatgeneration unit for transmission of power and data between the at leastone ORC unit and the at least one mobile heat generation unit, whereinthe controller comprises a first controller, and wherein the at leastone ORC unit includes a second controller, the first controller of theat least one mobile heat generation unit being coupled to the secondcontroller of the at least one ORC unit.
 10. The system of claim 1,wherein the at least one mobile heat generation unit further comprises abackup power system configured to supply power to the controller andincluding a series of sensors, and wherein the controller is configuredto open one or more drainage valves for release of the working fluidfrom the fluid recirculation system upon detection of a loss of powerfrom a direct power supply.
 11. A system to generate geothermal power,the system comprising: at least one mobile heat generation unit; and oneor more conduits configured to divert a flow of heated fluid from one ormore heat sources to the at least one mobile heat generation unit,wherein the at least one mobile heat generation unit comprises: a pairof heat exchangers mounted at elevated positions adapted to facilitateaccess, a pump configured to pump a flow of a working fluid through theheat exchangers, a first fluid path extending through the heatexchangers and along which the flow of heated fluid is received from atleast one of the one or more conduits and is directed through the heatexchangers, and a second fluid path extending through the heatexchangers and along which the flow of the working fluid directedthrough the heat exchangers for indirectly transferring heat from theflow of heated fluid passing through the heat exchangers along the firstfluid path to the flow of the working fluid passing through the heatexchangers positioned along the second fluid path to cause the workingfluid to be heated so as to change phases from a liquid substantially toa vapor; and an ORC unit including a generator, a gas expander, and apump; wherein a substantially closed fluid recirculation loop for theworking fluid is defined between the at least one mobile heat generationunit and the ORC unit when connected to the second fluid path of themobile heat generation unit, wherein the flow of the heated workingfluid into the ORC unit causes the generator thereof to generateelectrical power via rotation of the gas expander of the ORC operation,after which the working fluid is cooled so as to cause the working fluidto change phases to the liquid phase, wherein the liquid phase workingfluid is recirculated back to the at least one mobile heat generationunit for reheating, and wherein the at least one heat mobile heatgeneration unit comprises a transportable pre-packaged module.
 12. Thesystem of claim 11, wherein the at least one mobile heat generation unitincludes a substantially rectangular frame defining a working footprinthaving a length of approximately fifteen feet to approximately twentyfeet and a width of at least about eight feet.
 13. The system of claim11, wherein the system includes at least one additional ORC unitconnected to the mobile heat generation unit.
 14. The system of claim11, wherein the at least one mobile heat generation unit comprises askeletonized frame defining a chamber and having upper and lowerportions and side portions, and a plurality of cover panels mountedalong the upper and lower portions and the side portions of the frame,so as to substantially enclose the chamber, and wherein at least one ormore of the cover panels is configured to be removable from the frame toenable access to the chamber.
 15. The system of claim 11, furthercomprising a power and data connection extending between the at leastone ORC unit and the at least one mobile heat generation unit fortransmission of power and data between the at least one ORC unit and theat least one mobile heat generation unit.
 16. The system of claim 11,wherein the working fluid includes deionized water pentafluoropropane,carbon dioxide, water mixtures, tetrafluoroethane, isobutene, propane,pentane, perfluorocarbons, hydrocarbon mixtures, and combinationsthereof.
 17. A mobile heat generation unit comprising: a transportablepackage including a frame having upper and lower portions and sideportions positioned so as collectively to define a chamber therein andhaving a frame footprint, the package further comprising: at least oneheat exchanger located within the chamber at an elevated positionadjacent the upper portion of the frame to facilitate access to the atleast one heat exchanger; a connecting pipe extending between the atleast one heat exchanger and a heat source and configured to direct aflow of a high pressure or high temperature fluid from the heat sourceto the at least one heat exchanger; a controller having programmingconfigured to monitor temperature, pressure, or a combination thereof ofa working fluid passing along a fluid recirculation loop defined betweenthe mobile heat generation unit and at least one ORC unit and toregulate flow of the working fluid through the at least one heatexchanger for transfer of heat from the flow of the high pressure orhigh temperature fluid to the working fluid; and a fluid recirculationsystem comprising: a fluid intake conduit coupled in fluid communicationwith the at least one ORC unit to receive the working fluid at a firsttemperature from the at least one ORC unit, a fluid outlet conduit influid communication with the at least one ORC unit to supply the workingfluid thereto, wherein the working fluid is supplied to the ORC unit ata second temperature that is higher than the first temperature, a pumpconnected to the fluid intake conduit, the pump and configured to pumpthe working fluid received through the fluid intake conduit through thefluid recirculation system, and a piping array, including a firstsection of piping extending between the pump and the at least one heatexchanger for supplying the working fluid to the at least one heatexchanger, and a second section of piping extending between the at leastone heat exchanger and the fluid outlet conduit, at least a portion ofthe fluid inlet conduit extends adjacent an upper portion of the frameand connects to the first section of piping, and at least a portion ofthe fluid outlet conduit extends adjacent an upper portion of the frameand connects to the second section of piping, thereby as the workingfluid passes along the piping array and through the at least one heatexchanger, heat from the high pressure or high temperature fluidsupplied to the at least one heat exchanger from the heat sourcetransfers to the working fluid so as to heat the working fluid to thesecond temperature for supply to the at least one ORC unit.
 18. Themobile heat generation unit of claim 17, wherein the frame furthercomprises a plurality of cover panels positioned along the upper andlower portions and the sides of the frame, so as to substantiallyenclose the chamber, and wherein at least one or more of the coverpanels are configured to be removable from the frame to enable access tothe chamber.
 19. The mobile heat generation unit of claim 17, whereinthe at least one mobile heat generation unit includes a frame defining aworking footprint having a length of approximately 15 to approximately20 feet, and a width of at least about 8 feet.
 20. The mobile heatgeneration unit of claim 17, further comprising a power and dataconnection extending between the at least one ORC unit and the at leastone mobile heat generation unit for transmission of power and databetween the at least one ORC unit and the at least one mobile heatgeneration unit, wherein the controller comprises a first controller,wherein the at least one ORC unit includes a controller defining asecond controller, and wherein the first controller of the at least onemobile heat generation unit is coupled to the second controller of theat least one ORC unit.
 21. The mobile heat generation unit of claim 17,further comprising a backup power system configured to supply power tothe controller and having a series of sensors, including one or moresensors adopted to monitor ambient environment weather condition of oneor more drainage valves for release of the working fluid from the fluidrecirculation system upon loss of power from a direct power supply. 22.A method for generating geothermal power, the method comprising:locating one or more mobile heat generation units at a hydrocarbonproduction site, the one or more mobile heat generation units eachcomprises a package having at least one heat exchanger, a controller,and a fluid recirculation system including a pump, a fluid inlet conduitthrough which a flow of a working fluid is received in a substantiallyliquid phase, a fluid outlet conduit through which the working fluid issupplied in a substantially vapor phase, and an array of piping defininga fluid path extending from the pump through the at least one heatexchanger and to the fluid outlet conduit; connecting the at least oneheat exchanger of the one or more mobile heat generation units to a heatsource thereby defining a fluid path extending from the heat sourcethrough the at least one heat exchanger; connecting one or more ORCunits to the at least one heat exchanger; opening one or more valvespositioned between the at least one heat exchanger and the heat sourceconnected thereto to enable a flow of heated fluid along the fluid pathextending from the heat source through the at least one heat exchanger;pumping the working fluid along the fluid path extending from the pumpthrough the at least one heat exchanger and to the fluid outlet conduit;transferring heat, via the at least one heat exchanger, from the flow ofheated fluid to the working fluid when pumped through the at least oneheat exchanger, to cause a change in phase of the working fluid from aliquid to a vapor, which is thereafter supplied to the one or more ORCunits to drive a generator for generation of electrical power from theORC operation; monitoring temperature of the working fluid, pressure ofthe working fluid, ambient weather conditions, or a combination thereof;and operating one or more control valves to regulate the flow of theworking fluid through the array of piping to control the temperature orpressure thereof, or to drain the working fluid from the array of pipingupon detecting of subfreezing temperatures.